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This instructable will show you how to, from scratch, make a folding knife with cast aluminium handles. The making of this knife does not require many power tools and can be done mostly by hand. Have fun and be careful.
Step 1: Templates
I found a set of templates that were created by John Heisz. The templates are found for free on his website www.ibuildit.ca or can be found directly at this link: http://www.ibuildit.ca/other%20projects/Images/Pocket%20Knife/folder.pdf
Step 2: Cutting Out Knife
The first part of this process is to find a piece of flat steel. It is better if you can use old saw blades or tool steel but for this project I simply used a piece that I found in a junk pile near my house. It is 3 millimeters thick, perfect for a knife blade. Before you cut it out, glue on the template onto the steel, and let it dry. I used a jig saw with a metal cutting blade on it but you could alternatively just use a hacksaw. I followed the lines as best I could, and after that, I used a metal file to fine-tune the edges.
Step 3: Sharpening
Next, I clamped the knife in the vise and slowly used a metal file to grind the steel to a point. I could have done it faster with an angle grinder but I didn't want to risk messing up the whole blade. It is a good idea to mark the center of the steel with a marker before so that the edge of the blade is centered once it is finished. After all of the rough filing was complete, I smoothed the blade with my bench grinder. You don't want to sharpen the knife all the way just yet. Keep is dull for now.