The idea for this began when I made a stop in a local outdoors store and saw the Light My Fire Spork. Naturally, I didn't want to pay the price markup for something I thought I could make on my own with things I already have.
Step 1: Materials & Tools
- (1) metal spoon
- (1) metal fork
- (1) package J-B Weld two-part epoxy
- (1) Dremel rotary tool
- Cutting Wheels
- Tungsten Carbide Cutters
- Grinding Stones
- (1) Bench Vise
- (1) Metal File
- (1) Permanent Marker
Step 2: Draw Removal Lines
Then decide how much of the handle you want to remove. Bear in mind that these are going to get epoxied together so make sure the parts of the handle that are left are about the same length.
Also, I decided to carve out a bottle opener behind the tines of my fork since, well, who knows if I'll need it. Better to have it than not, and I'm not too troubled about it affecting the structural integrity of the fork.
Step 3: Cutting
Then use the tungsten carbide cutter for removing the bottle opener. You can also remove a good majority of it with a drill and steel drill bit if you have them.
Step 4: Create a Knife Edge
Using the cutting wheel, make little serrations along the edge of the fork (do it on the edge that doesn't have the bottle opener on it). Next, use the grinding wheel to shave a slight angle into the edge - not too much though, as you don't want to cut your mouth when you use the fork.
Step 5: Flatten the Handle Remnants
You want them as flat as possible so when you epoxy them the epoxy doesn't have to span as far a distance and you'll get a stronger bond.
After you flatten them, use the grinding stone to rough up the attaching faces of the backs of the handles and then clean them with some sort of solvent (rubbing alcohol or acetone are good choices). Leaving the faces smooth won't give the epoxy much to grab onto so get them so you can feel the roughness when you run your finger across. The last pic shows one of the ones I made that came apart because I didn't rough the faces.
Step 6: Epoxy Them Together
According to the packing, J-B Weld needs 4-6 hours to dry before handing so find something to do during that time. I went to sleep and went back to the project the next day.
Step 7: Smooth the Rough Edges
Be sure you smooth down the cut ends of the tines too so you don't cut the inside of your mouth.
Step 8: Optional: Give It a "Brushed" Look
Step 9: Finished!
Mine ended up being a little less than 6 inches long and weighs...well, I can't tell you exactly how much it weighs since I don't have a scale. A couple ounces at most but definitely less than a separate, knife, fork, and spoon.
I think one could soften the handle with some Sugru but I don't have any. Maybe in another update.
Well, only thing left to do is grab some grub, a bottle of beer, and enjoy both using your brand new Knorkoon!
Also, if you like this, don't forget to vote for it in the What Can You Do With a Dremel Tool? contest!