Well let's get started with my Up-Cycled Bowie knife.
Step 1: Nut Turned Guard
For the first step I cut one side of the nut. I opened it up in subsequent heats. At this stage I felt like it looked more like brass knuckles, but transitioned it into a guard similar to that on a Nazi Zombie Bowie Knife.
With that final decision, I hammered the edges to a taper so it could attach to a blade. (Not specified in pictures)
Step 2: Blade Profiling
I selected a section of truck leaf spring. After scrawling on a design I cut out the shape with a torch. I cleaned up the profile with a grinding disc on an angle grinder.
Step 3: Welding
Prep: I cut notches into the guard, so it slid together as one, almost like a mortice and tennon.
Weld: I simply welded the pieces together making sure to extend the weld down onto the blade, for aesthetics and slight function.
Grinding: I used an angle grinder to clean the weld, achieve a better look.
Step 4: Forging Bevels
Essentially all one does is slide the blade edge onto the edge of the top anvil surface, and angle slightly. Hammer blows from the other side, match the angle, making the same effect on both sides.
It is good practice to flip the blade over, to eliminate inconsistencies that occur from each side.
I did this on each side, as well as the tip, so I had less to grind later.
Step 5: Stock Removal
I grinded the surface of the blade, increasing grit of belt until desired.
I used the wheel on the grinder to clean the surfaces of the nut, as they had curved in forging. The forging also damaged the edges, so this helped clean that.
I cleaned all sides of the guard, and used a flap disc on some of the harder to clean sections, like the weld.
All parts of the knife was finalized with a Scotchbrite belt.
Step 6: Hardening
I heated the blade evenly to a medium orange, and submerged it in the tank. Moving the blade around in the tank prevents the bubbles from insulating the steel
I used a propane torch to pull some of the hardness out, by heating the center of the blade to a dull plum color.
Step 7: Cleaning
Step 8: Handle Attachment
I drilled holes in the wood, matching those in the steel.
I cut pins from aluminum tent stakes, which have a size of 1/4''. I secured it together and started shaping down the wood with a flap disc, files, and sandpaper.
With it closer to size, I glued it together with a two part epoxy. Typically I wrap the blade, but with this one,i just oiled it to stop the glue from sticking. I let it dry clamped up, and checked on it. I let it cure for a few more hours.
I then used a large circular file and 1x24 belt (cut) to do the rest of the shaping.
I used increasing grit sandpaper to finish the handle.
Here's where I confess. I drilled the holes horribly. It's not my first rodeo,but for some reason it just didn't line up well. The wood had to be drilled out larger then the pin. Between three pins it was still solid, but frustrating nonetheless. I was already planning on wrapping the handle with leather, so it didn't really effect my end result. I kept on trucking.
Step 9: Leather Wrap
I cut a piece of leather large enough to wrap around the handle with my desires dimensions. I trimmed the part where the handle was thinner, to compensate.
Using a fork, I marked all the spots to punch. Leather is very strong, so typically the holes are punched first. I used a punch over a wooden board. Approximately equal holes on each side.
I used way to much thread on this part. You'll probaly do the same. Six inches of thread per inch of handle should be plenty. I had like 6 feet of it. It was ridiculous, don't do it.
I used two needles, with the center of the thread obviously at the first stitch spot. I tied a square knot over this stitch using the thread. Using the two needles I stitched it like tying shoes. Cinching tight each time, I finished, and tied a knot on the bottom. Well, not really. I broke one of the lines at the end, and had to stitch the other around a whole bunch. Don't make my mistake.
I sealed the bottom with a little super glue. Maybe overkill but anyways.
Step 10: Complete
Questions? Comments? Advice on something I did stupid? Please do tell. I'm always looking to explain something in more detail or learn something new.
Most importantly, thanks for reading, and happy crafting to all