1 1/2" X 1/8" flat bar
1/8" brazing rod
3/8" X 2" X 5" oak
5 minute epoxy coat
Good exterior varnish
Two sided tape
1 1/4" fiber cutting disks
1X32 bench belt and disk sander and
Aluminum Oxide sandpaper (80 to at least 600 grit)
Black, white and lastly blue polishing compound
Drum sanding kit
High speed drill bits (1/8" and 1/2")
Side cutters Clamps
Sisal, spiral sewn, and loose buffing wheels
First, plot out the blade and handle shape on graph paper. Draw it to actual-size. When people see a knife, the first thing they see is the blade. Therefore, it should set the theme for the knife, and make the knife look great. Then transfer it to mate board, cut it out using a utility knife and hold it in your hand to see if it feels right; if not back to the drawing board. This may take a few tries until you are satisfied.
Now you are ready to make your knife. Cover your metal in painters tape, lay the pattern on top and trace around it using a pencil.
Start cutting our your knife. 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). Take your time, start at a slow speed until you have a grove cut, and then you can increase the speed.
I use a rotary tool rather than an angle or bench grinder, as you can get allot closer to your pattern, it do not tend to over-heat the material, and saves time cleaning up your knife.