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From File to Knife (with simple tools)

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A good "bushcraft" knife is a must-have for every outdoorsman.
It's a tool that lasts a lifetime.
Wouldn't it be awesome to make such an essential, lasting tool yourself?

There are many different types of knives and many ways of making them.
This instructable will show you how to make an excellent, inexpensive (<$20) bushcraft knife with simple tools (such as a hacksaw, file, drill and vice).
The design is based on the popular (but expensive) Ray Mears Bushcraft knife.

So if you have a few basic tools and plenty of elbow grease, lets make the [Your Name Here] Bushcraft Knife :)


I have entered this instructable for the Great Outdoors Contest and the I Could Make That Contest.
If you like this instructable, please vote for it!
 
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Step 1: Tools and materials

Here's a quick overview of the tools and materials that I used.
They'll be discussed a bit more later on in the instructable.

-Old file
-Piece of hardwood
-Two-part epoxy adhesive

-Coal
-Forge (something to burn the coal in)
-Air pump
-Tongs
-Quenching oil
-Kitchen oven

-Scriber, permanent marker
-Caliper
-Vice
-Clamps

-Hacksaw
-Lubricating oil
-Files
-Sandpaper
-Drill
-Hammer
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seth33706 days ago

this is fun. my dad has about 40 old files. now he only has 26. :)

This is cool, is there anyway you can get rid of the file edges on the finished product?
casvandegoor (author)  justintime199811 days ago
Ofcourse: you can just file them off ;)
Flash6722 days ago
Wow! You did an amazing job on this i can see you really put your time into this instructable and I can tell you very passionate about this! I'm gonna have to try this someday. This instructable is also a very good example of good instructables I want my first instructable to be like this:)
casvandegoor (author)  Flash6721 days ago
Thank you very much :D I'm glad that I've inspired you to make good instructables.
dhakim made it!3 months ago

Finally finished! Thanks for the idea...it was a great learning experience.


file knife.png
casvandegoor (author)  dhakim3 months ago
Awsome! Nice Work!
Emsaid3 months ago

Great ible! Just finished annealing mine, I'll post a picture when I'm finished with it.

casvandegoor (author)  Emsaid3 months ago

Nice! I'm curious how it turned out.

Mattrox4 months ago

This is awesome! I love the finished knife and how you used fairly everyday tools. Thanks for posting!

clockworkfish4 months ago

Such a great job on this!

Johnhall145 months ago
Good instructable : )
casvandegoor (author)  Johnhall145 months ago

Thanks!

=)

Advar7 months ago
Nice 'ible! Question: If one wished to make a hand ax, with a stronger edge, what griding angle would be best with a dremmel? For a camper friend next Xmas.
The block is 6"l, 4"w 1\2"t.
casvandegoor (author)  Advar7 months ago
Thanks! I'm not an expert, but this is what I found: The grind angle ranges from 12 to 20 degrees (so the included angle ranges from 24 to 40 degrees). It depends on what you want to do with the axe. For carving you'll need a steeper grind angle (12 to 15 degrees), while for chopping (hard) wood a less steep angle is preferred.

http://www.axespecialists.com/axe-sharpening
http://www.gransforsbruk.com/en/axe-knowledge/caring-for-your-axe/sharpening/
So I'd want to use 12-15°. Thanks!
ZakSett7 months ago
Nice work many thanks, tips from expert , well explained
mykiscool8 months ago
Prisoners everywhere hail you as their hero! Just kidding though, nice instructable.
casvandegoor (author)  mykiscool8 months ago
Haha, thanks!
That is very interesting. I think if I make one I will just cut off the tang of the file, and make a very straight knife with the old file surface for grips, and finger grip indentions. No woodwork would be necessary then.
casvandegoor (author)  Yard Sale Dale8 months ago
That's also a possibility. Good luck!
flatboat11 months ago
As a metallurgist, it is a real pleasure to see someone on these forums give well thought out useful and accurate knowledge, in a clear and concise fashion, to people wanting to do a good job! Well done!
casvandegoor (author)  flatboat11 months ago
Wow, thanks!
I just published my own knife building ible. Not nearly as well worded as yours though. Good job.
cjones9210 months ago
"Forge" sort of throws this a bit out of the "basic tools" realm, don't you think? Heh heh!
casvandegoor (author)  cjones9210 months ago
By "forge" I actually mean anything you can burn the coal in. So in this case it can be a barbecue, a couple of stones or a hole in the ground. You can even heat the steel in a simple campfire as well.
I am using this as a forge for my knife(s), I would suggest two burners though.

https://www.youtube.com/watch?v=jBVa2bw3r_k
jyxk10 months ago
great!I want to make a knife like this!bushcraft
cjones9210 months ago
Cool (er, uh... Hot?) project!
casvandegoor (author)  cjones9210 months ago
:)
Ray from RI11 months ago
Outstanding!!! Well thought out and illustrated... a great post....!
casvandegoor (author)  Ray from RI11 months ago
Thanks!!!
You certainly made an outstanding sloyd type of knife...!
monkeyking1010 months ago
If you were to make this knife full-tang, would you need any wood for the handle or bolsters, or would you just cut it in the shape of the handle?
Great Instructable!
casvandegoor (author)  monkeyking1010 months ago
Normally you secure wooden/composite scales to both sides of the tang, for a better grip and more comfort.
I can imagine that you don't necessarily need it on a small knife that you use for small jobs.
Would it be possible to serrate the knife by filing part of it to a serrated edge with a rat tail file?
casvandegoor (author)  monkeyking1010 months ago
I've never done it, but I think it's perfectly possible :)
Gaark10 months ago
I've got a spare file at home, I'm going to try this!

Thanks :)
+vote
casvandegoor (author)  Gaark10 months ago
cool! good luck and show us what you've made!
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