First is hammering out the steel into the rough shape desired. I started with a bar of Damascus steel about 1/2 in thick.
(Damascus steel is a type of patterned steel and is actually alternating layers of high carbon steel and nickel all forged together.)
I used a coal forge for almost all of the work. After bringing the steel up to a yellow heat I started to work the front end of the steel into a tip.
Keep all hammer blows flat, in order to keep the steel flat. (Rocket science right? ;)
At all times I tried to keep the steel flat and level on both sides. After the tip was formed I started to finished the blade profile and after that I
moved onto profiling the handle part. When it was looking more like a knife :D....I cut it off of the bar.
The next step is grinding out the profile. I used a 2x72 belt grinder to refine the knife shape into what I wanted. I grinded the sides of the knife flat a got sanded it from 60 up to 400 grit.
Next step-grinding gown the bevels for the edge. I did this by using a file instead of a grinder because it is a much finer way of working with
less possible failure. Sharp hand tools are a great thing. I got the blade edge down to about 1/32 of an inch. I again sanded the whole thing
to 400 grit. Heat treatment followed. I brought the knife temperature past the nonmagnetic point and quenched it in oil. I then tempered it at 400 degrees or so.
Following that it was time etching out the true look of the steel. I re-sanded the 400 grit because the heat treating re-blackens the steel. For that I used a Radio Shack etching solution. It was half etcher, half water in order to have the steel be darker.
Next was the handle work. To attach the handle I drilled holes in the hardened steel with a carbide bit. DRILL HOLES BEFORE HEAT TREAT. The handle scale material is Bloodwood. I cut the wood scales with much excess material on all sides. I drilled holes in the wood to match the steel and cut sections of brass pins to fit.
When everything fit snugly together I used a two part epoxy to glue it all. Before gluing I wrapped the blade in paper towel then with masking tape.
I let the glue set then started shaping the handle with a 1x30 inch sander on 80 grit to the desired size. After it was achieved I sanded it with 120 grit and then by hand, 220 , 400, and 1200. I then finished it with linseed oil to protect both the blade and the handle.
Any questions?? well happy crafting everyone,