Step 1: Get yer stuff
your gonna need;
A butterknife, thats good quality - the width of the blade should taper towards the end, and be quite thick.
about a foot of 1"x1/6" ish hardwood stock. I used jetoba, which is pretty, but anythng will do
some good, fast drying glue. i used '5 minute polyurethane'
*optional is a bit of thin veneer(?)y stuff in a contrasting colour to you handle
tools n things;
A dremel, essential (unless you have a lot of files and and a months worth of patience)
with a grinder bit, a cut off wheel, a polishing wheel and a sander thingy.
a fretsaw (you could use a hacksaw)
an old sock
a gas cooker
umm. and some goggle. bits of metal in your eyes is not fun. casualty and a sadistic nurse with tweezers will await you.
Step 2: Blade blank. yay!
after that, get some wet and dry sandpaper and make the cutting edge smoother and sharper, then go over the whole blade, and polish it, because once it's hardened, thats it it. so make it nice and shiny.
jeez, these images are slow to upload.