How to Make Steel Knuckles

Introduction: How to Make Steel Knuckles

About: Ancient war god, incessant tinkerer, scientist, commited metal head, backyard engineer, chain smoker, guitar builder

Disclaimer : These are not a toy, and this isn't a mockup made of out of harmless materials, These are dangerous and nasty and I would hope after the fabrication of these you behave rationally. Steel is dense, bone is brittle. That being said lets begin. Im aware that one method of cutting,drilling or finishing metal might not be available too you so i attempt too offer alternative methods for fabrication. Please excuse the poor images im no photographer.

Bill Of Materials :
1. 1ft long by 4in wide by 1/4in thick plate steel.
2. 1in diamter bi-metal hole saw
3. A way to weld, or you could use 1/2in thick (much harder too cut ) or simply leave them 1/4in thick.
4.A way too cut metal ex. metal cutting jigsaw,sawsall or hacksaw(for those of you with real gumption :) personally i'll be using a bandsaw with a 24 TPI blade.
5. Metal center punch and hammer for marking center points in the plate steel.
6. 3/4inch drum sander with 80 grit sandpaper
7. scribe,sharpie or pencil(hardest too see,wouldn't advise it ) if a scribe is used get one where the tip i made out of tungsten so it wont round over on the mild steel.
8.A ruler that can measure in millimeters if you dont want too purchase one you can download one at www.boltdepot.com
9.Square or straight edge
10. posterboard, cardboard or computer paper for the template

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Step 1: Steel Preparation

When you purchase steel from your local hardware its coated in zinc oxide too protect it from corrosion that might occur on the shelf. Use your 80 grit sander too remove this coating until you are left with bare steel. If you are gonna draw the silouhette of the knuckles on with a sharpie i would wipe it down first with rubbing alcohol or minerals spirits.

Step 2: The Template

Use a 1" bi-metal hole saw too punch out finger holes and the two outside are parallel and the 2 center holes are paralell but higher than the other two by about an 1/4". After you mark out the holes draw the material outside the finger holes and the grip.

Step 3: Marking Drill Points and Cutting the Profile

Now with your template cut out and the center points all marked out secure the template by taping it too the steel. Use your punch too mark the center points and where it will curve inwards. Drill the smaller diameter holes first, then onto the 1in holes. Remember: When drilling steel keep your drill at a very slow speed, too fast and you will anneal the cutting edge of the bit or saw and render it useless. Now on too cutting the profile. Cut just outside your line too allow for sanding and filing too the final shape. If you are doing like me you have too cut two out of 1/4in plate.

Step 4: Deburring and Filing

Unless you cut it out perfect take this is your opportunity too debur the fingerholes and shape the areas with a file that didn't come out right.

Step 5: Plug(Rosette)welding

*If you cut your knuckles from one plate than this step does not apply too you.
This step I could not photograph because all you would see is a ball of light in the photo.
Here's the gist of whats happening though, you are using molten steel as a fastener between two pieces of steel. When you are doing this dont tack weld or stop. Dont worry about overfilling the weld you should sand it down with 120 grit after you are done.

Step 6: Polishing

At this point if both of the plates are not perfectly lined up you can shape them with the 80 grit till they are flush together. After you have shaped them sand them down with 120 grit then polish them with #4 and #1 abrasive wax polish with a cotton wheel. #4 is black and #1 is green spend it about 3 million hours polishing them and they look like this

Step 7: Now Its Over

Have fun but be responsible. If you want a good finishing tip head to caswellplating.com the last portion of this project was going too be me electroplating the steel with brass but i ran out of money. If any of you cyber punks get your hands on a brass plating wand and do this forward me photos i would love too see what one would look like with a brass coat.

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    20 Discussions

    0
    slo5oh
    slo5oh

    6 years ago on Introduction

    Know your state laws before you build these.
    Illegal in California
    Cal PEN Code 12020

    0
    Ciege666
    Ciege666

    Reply 5 years ago on Introduction

    Most people get around this by not owning brass, or steal, knuckles but rather owning a paper weight, technicality but it works in some places...

    0
    armourkris
    armourkris

    6 years ago on Introduction

    I just cheated when I made mine and used a cutting torch and a die grinder to clean them up. I went with the skull face design, 2 fingers through each eye socket and the teeth into your palm, they make a good paperweights.

    0
    Oldman the madman
    Oldman the madman

    6 years ago on Step 7

    Hmmm thanks for that, I think I found something for my cousins birthday.

    0
    Oldman the madman
    Oldman the madman

    6 years ago on Step 7

    Very interesting now I know how to make them, but the new problem is getting the tools and materials to do it.

    0
    n3rdd
    n3rdd

    Reply 6 years ago on Step 7

    It would be possible to do with just a drill and a hacksaw if you used rivets instead of plug welds. You would probably want to countersink them though.

    0
    abstracted
    abstracted

    7 years ago on Introduction

    nice job...i make knives and have always wanted the knuckle duster version trench knife...off to the shop i go. like my brass gears one can drill a series of small holes and punch em out, for those with limited tools.

    0
    black hole
    black hole

    8 years ago on Introduction

    Where did you get that steel? I'm always looking for metal to make knives.

    awsome. totally awesome. this is like the only ible when someone actuallly makes real ones. which type of drill piece did you use. did you use the paddle type or the cylender type.

    0
    curt-fullmer
    curt-fullmer

    Reply 8 years ago on Introduction

    Dont use the paddle bits(spade bits) they're not tempered to cut steel. Also the cylinder bits come in two different types. Use the white cylinder bits only(bi- metal hole saw) the black ones are for wood and the teeth will shred off with mild steel.

    0
    shadow wave rider
    shadow wave rider

    Reply 8 years ago on Introduction

    ok cool. ive got small fingers so a large normal drill piece should do. i don't want them banging against my fingers because they will hurt. also i've slightly alered this. your know how you used two layers, i cut a space in between to slide in a little spike. not sharped becuase you dont want blood everywhere but it will hurt.... alot. mwhahahahahaha. so you better be nice to me.lol. mwhahahahahahahahahahahahahahahahahahahhahahahahahaahahaha(cough, cough.)

    0
    curt-fullmer
    curt-fullmer

    Reply 8 years ago on Introduction

    Thats so awesome. Super excited to see what you come up with.

    0
    srohwer
    srohwer

    8 years ago on Introduction

    I could see fabricating the template out of corrugated cardboard. Lots of chances to experiment, design, etc. before the fabrication.

    Do you think a product like JB Weld would be sufficient to hold them together?

    Very nice 'ible. Thanks!

    0
    curt-fullmer
    curt-fullmer

    Reply 8 years ago on Introduction

    Cardboard or posterboard for metal fab is very helpful, if you ever watch any auto shows they always use cardboard first ex.floors,hood scoops etc.

    0
    codongolev
    codongolev

    Reply 8 years ago on Introduction

    if you wanted, you could bolt or rivet them together.

    0
    Scott_Tx
    Scott_Tx

    Reply 8 years ago on Introduction

    yeah, I was thinking rivets too. It'd look cleaner I think

    0
    curt-fullmer
    curt-fullmer

    8 years ago on Introduction

    You know i didnt even think about that you could bolt or rivet them together. Good thinking. You could try JB Weld maybe in time they would come apart but is suppose you could just JB weld them again.