Picture of The making of ��� (pork belly)
��� (pork belly) This is the nineteenth knife I made. It is sitting on a piece of  channel iron (3 1/4" X 1 1/2" and 1/8"  thick) of which the knife is made
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Step 1:

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Step One: I drew out a design on Bristol board and cut it out using a utility knife.  Then held it to see if it feels good and made any adjustments.

I  laid my pattern on the material and traced around it with a marker. I am using a piece of  channel iron (3 1/4" X 1 1/2" and 1/8"  thick) that I got as scrap at work.


Step 2:

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Step Two: I cut out the pattern with a "Dremel" type rotary tool, using the fiber type cutting discs (The fiber discs last a lot longer than the cheap ones). I use a rotary tool rather than an angle or bench grinder, as you can get allot closer to your pattern, and it do not tend to over-heat the material.

Step 3:

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Step Three: I have finished cleaning up my pattern. I using a 1X32 belt sander and disk sander, plus a drum sanding kit on my drill press.

Step 4:

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Step Four: I have drilled holes in the handle section to pin my handle material; shallow holes in the handle section to help my glue stick; and milled decorative holes in the blade section. Then sanded the material down with Aluminum Oxide sandpaper, starting with 80 grit and working down to 400 grit (I only sanded the handle section with the 80 grit to remove the rust, leaving a rough surface to help my glue to stick). bevel the edges of the blade using a 1X32 belt sander.  Finally polished the blade section with black, green and lastly blue polishing compound using buffing wheels on my drill press.

I would now temper and heat treat the metal if I had access to a kiln, and then have to re- polish the blade.

Codswallop2 years ago
This looks beautiful. Do you actually peen the brass pins over to make them structural, or are they only decorative?
I know it's not my instructable but he seems to have done what I do. The pins just provide directional support. Most custom knife pins are not peened over, contrary to some belief.
WazIt (author)  Basement_Craftsman2 years ago
The brass pins are not for decoration, nor do I peen them. They do provide support to the scales. I flute the pins and glue them, and find they have yet to fail
ZaneEricB2 years ago
do you need to re temper the iron?
ZaneEricB2 years ago
ummm...so this is badass...

anyone else?

nice work tex!
EmcySquare2 years ago
Great job, like it a lot. Too bad you could not Heat Treat it !!
WazIt (author)  EmcySquare2 years ago
thank you, yep my knigdom for the use of a kiln
This is how I made my (hugly) one. Be sure to use INSULATING (type jm23) briks: http://www.instructables.com/id/Electric-Kiln-the-cheaper-ever/
I forwarded him those planes long ago. He's one of those people whom like to do everything as safely as possible. I doubt he will ever hand build a kiln. It makes me sad. This is what he helped me build when I visited him ( he's my father )

Well, that kiln is not designed to be sasfe, that's true. Still I've been using it for 2 years now with no problem at all.
It can't esplode, nor can catch fire is you don't put flamable materials there.
The main risk comes from electricution, but it's easy to avoid if you do it right. You can add a circuit breaker (is that it's name?) that will cut power when he detects a short circuit or such.
Or you could do it with a forge... many ways to do that.
Another solution, even better, could be to send it over to some het threat company and have it done for you.

BTW: very nice job of yours !!
blkhawk2 years ago
It looks a lot to a parang. Nice job!

Parang? I'd rather say a kukri !! :-) http://en.wikipedia.org/wiki/Kukri
crankyjew2 years ago
what about heat treating, and tempering? what sort of steel is channel iron?
Kiteman2 years ago
That looks really nice - how well does "channel iron" (a term I've not heard) keep an edge?