So I've had an old and lonely chef's knife hanging out in my knife kit for a while now. I retired it and bought a new one shortly after a coworker used it to pry open a stuck robot-coupe and cracked off the tip off. People are no longer allowed to use my knives to say the least...hard lesson learned indeed! Well, I was looking at this knife the other day and thinking about how perfectly usable it is, except for the fact that it has no tip...an essential item for speed and/or precision knife cuts. Soooo I thought...why not? No job Dremel can't handle! And so it was...pulled out of retirement and fully repaired, my trusty work companion and arm extension is back in action! In this instructable I'll show you how to save a few bucks by repairing your own knives.
Step 1: Gather Materials
To put a new tip on your knife you'll need the following:
Marking device such as a pen or marker
Dremel Attachments (metal cutting blade, grinding bit, sanding bit, wire polishing brush, synthetic polishing brush, and felt polishing tip with polishing compound applied)
A clamp for supporting the knife
A sharpening stone or other sharpening device
A honing steal
Step 2: Mark the New Tip
Using a sharpie or other marking device, draw on a new tip. Shade in the section you want to remove. If you want to see the end result put a cloth of the same color as the pen and then hold the knife up to it (e.g. I used a black sharpie so I held the knife up to a black cloth), you will be able to see the shape of your new knife. I wanted to preserve the length of this knife and also avoid having to put a new cutting edge on it, so I opted to shave just a little off the top.
***Note: Using this method will slightly change the shape of your knife. To preserve the shape, take some off the top and bottom, then put a new cutting edge on it yourself or have a professional do it for you.
Step 3: Clamp the Knife to a Work Surface
Clamp the knife firmly onto your work surface. I do not reccomend holding the knife in your hand while trying to do this for two reasons 1. It is extremely dangerous! 2. You may end up with a jagged or uneven edge.
Step 4: Removing the Excess
Use a dremel with a metal cutting blade attached to it to cut off the dark shaded area. Run the dremel full speed, however slow and steady motions with very light pressure will produce a nice rounded cut.
Step 5: Grind, Sand, and Polish
The hard part is over. Now use the dremel with following attachments (in numerical order) to clean up the cut.
1. Grinding bit
2. Sanding drum
3. Wire polishing brush
4. Synthetic polishing brush
5. Felt polishing tip with a small amount of polishing compound applied to it
***Note: I ran my dremel 3000 at a speed of 4 when doing this and ended up with an identical shine.
Step 6: Sharpen the Cutting Edge
Now run your blade along a double sided sharpening stone a few times to bring back the tip's edge. I used an aluminum oxide, two sided sharpening stone followed by a diamond impregnated honing steal to get it nice and sharp.
Step 7: BAM! Like New!
Aaaaaaaand Bam! Just like that...a knife brought out of retirement, with a whole new look too.