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Main Boards => Hunting Knives and Crafters => Topic started by: Emmons on July 14, 2008, 01:39:00 AM

Title: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: Emmons on July 14, 2008, 01:39:00 AM
Knife from a File Build-a-long

The following will show how I make a knife from a file.

Tool List:
Drill Press with assorted size drill bits
4” Angle Grind with cutoff wheel, sanding disc, and grinding disc
1” X 30” Belt sander with 6” Disc sander combo
Dremal Tool with assorted bits
Wet sand paper in 150, 240, 320, 400, 500, 600, and 1200 grits
Various Files
Vise Grips
Super Glue
Two part epoxy
Sharpie Marker
1/8” MDF
Safety Glass
Work gloves
Micrometers
Hacksaw
Hammer
Center punch
C-Clamps
Water Stone
Old File

I start will an old file that is large enough for the knife I plan on building.  In this case the knife is 8” long with a 3 ¾” blade, 1 1/8” from spine to the belly.  The file is annealed in my charcoal forge, by heating it to non-magnetic.  Once the non-magnetic temperature is reached the file is then buried in a bucket of hardwood ash.  This allows the steel to cold slowly.

      (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0757.jpg)

I designed this knife with a free CAD program and printed it out.
      (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0782.jpg)

Cut out the print and glue to 1/8” MDF, cut and shape to the print to make a pattern.
      (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0785.jpg)

Using the pattern outline the knife on the file.
      (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0786.jpg)
      (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0787.jpg)

Start cutting out the knife using the 4” Angle grinder and Dremal.
      (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0788.jpg)
      (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0789.jpg)
      (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0790.jpg)
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: Emmons on July 14, 2008, 01:40:00 AM
Using the belt/disc sander grind the knife to the final shape.
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0791.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0792.jpg)

Now I remove the file grooves and start thinning the material with the Angle grinder and a sanding wheel.
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0797.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0793.jpg)

After grinding the file grooves.
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0798.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0799.jpg)

Next I start to flatten the steel using the disc sander.  This also reduces the thickness closer to final thickness I want.
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0800.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0801.jpg)
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: Emmons on July 14, 2008, 01:41:00 AM
(http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0802.jpg)

Continue working on making both sides flat and parallel by mark the whole knife and remove material with a large flat file.  I try to get about 90% flat before moving to the next steps.
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0804.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0805.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0806.jpg)

Draw bolster on the knife, mark, and center punch pin locations.  On this knife I will peen two 1/8” brass pins for the bolster and use three ¼” mosaic pins for the handle.
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0807.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0808.jpg)

Drill holes to size and added large diameter lightening holes between them.
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0810.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0815.jpg)
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: Emmons on July 14, 2008, 01:41:00 AM
I then grind away material in the center of the handle area.  I do this by first using the angle grinder and then the small diameter wheel on the belt sander.  This helps to lighten the knife more and gives it a good balance point.
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0816.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0818.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0819.jpg)

Mark the complete handle area and flatten with a large flat file until there is a flat perimeter where the handle will be.
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0820.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0821.jpg)

At this point I layout and start the file work on the spine.  Here I’m making a simple pattern. I like to do the file work at this point, because there is still enough material to make changes if I screw up the pattern.
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0822.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0823.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0824.jpg)
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: Emmons on July 14, 2008, 01:42:00 AM
After completed, I color in the file marks and sand the spine with a sanding block.  This shows me how it will look when the knife is completed.
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0826.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0829.jpg)

Layout and rough grind the bevel using the belt sander.
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0830.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0832.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0834.jpg)

I then finish the bevel on my homemade file jig.  The jig allows me to maintain an angle to get a perfectly flat bevel grind.
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0835.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0836.jpg)
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: Emmons on July 14, 2008, 01:43:00 AM
Finished bevel.
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0838.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0842.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0839.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0840.jpg)

Next I use a water stone to make sure both sides of the knife are flat.  This also helps clean up the file marks and reduces the sanding required for a nice finish.
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0843.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0845.jpg)

Now the knife is clamped and block sanded.  First I sand the ricasso and flat, and then sand the bevel.  Starting with 150 grit sanding in both directions until all the stone and file marls are remove, then progress to finer and finer grits sanding in one direction (handle to point) until all mark from the previous grit are removed.  I only sand to 500 grit now as this procedure will be repeated after heat treating the knife.
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0877.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0878.jpg)
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: Emmons on July 14, 2008, 01:43:00 AM
(http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0881.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0883.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0884.jpg)

The knife blade is now finished until after heat treating.

Now we are going to make the bolster.  For this knife we will use brass with a rounded front and angled back.

I start by cutting a round that is 3/8” thick from a piece of large diameter brass stock with a hack saw.  Then split this in half to get both bolster.
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0846.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0847.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0848.jpg)

Then use the disc sander to grind one side of each bolster flat.
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0849.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0851.jpg)
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: Emmons on July 14, 2008, 01:44:00 AM
Position the bolster on the knife in the position you want, hold in place using vise grips.  Then mark the top and bottom shape.
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0852.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0854.jpg)

After marking the top and bottom remove the extra material to get the bolster close to the final shape.  I use a hack saw and dermal tool here.
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0855.jpg)

Now I super glue one bolster to the knife blade in the position that I want.  When the glue is dry I drill the bolster using the holes in the knife as a guide.
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0856.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0857.jpg)
Next glue the other bolster in place.  Line up the front of the bolster as close as possible.  After the glue dries drill the bolster using the previously drill bolster and knife as a guide.
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0858.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0859.jpg)

After the holes are drilled use a punch on the inside of the bolster to knock them off the knife.  Sand off any glue and fit the bolsters together with some pins or drill bits.
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0862.jpg)
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: Emmons on July 14, 2008, 01:44:00 AM
With the bolsters pinned together shape and final sand the front.  Also grind the rear of the bolsters flat.  Then relocate on the knife.
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0865.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0868.jpg)

With the bolster pinned on the knife, shape the top and bottom to match the knife.  Here I use the Dremal with a sanding drum.
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0873.jpg)

The bolsters are now complete until final finishing and assembly of the knife.  Remove them and pin together.
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0874.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0875.jpg)

More to come!!
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: robtattoo on July 14, 2008, 04:26:00 AM
:clapper:   :clapper:

Excellent tutorial James. Looking forward to th rest!
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: Danny Rowan on July 14, 2008, 06:26:00 AM
Rob, how was Africa, have not seen your story????

Great tut.

Danny
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: madness522 on July 14, 2008, 06:47:00 AM
Great start.  Thanks for including the finer details and not just skipping thru the highlights!
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: Leftieshot on July 14, 2008, 06:53:00 AM
Great job!  I like the bevel, finishing jig!
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: skullworks on July 14, 2008, 06:59:00 AM
Saaawwwweeeettttt tutorial! Great job and a fantastic looking blade!
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: Emmons on July 14, 2008, 09:32:00 AM
Thanks Guys!!

It will be a day or two until I can post the heat treating, handle, assembly, and finishing parts.  I am be no means a real knife maker, I have only made around 10 knife so far.  All of them from files.  I have added some tools since the first knife and plan on adding more, so the steps I take change a little over time.  Maybe I will keep this one for myself, as I do not have a knife I have made.  I have given them all away so far.

James
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: skullworks on July 14, 2008, 10:00:00 AM
You my friend are indeed a knife maker! Without a doubt!
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: Chris Surtees on July 14, 2008, 01:30:00 PM
:thumbsup:     :clapper:    :clapper:
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: JEFF B on July 14, 2008, 03:30:00 PM
awesome right there!!  :clapper:
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: OconeeDan on July 15, 2008, 07:50:00 AM
Nice tutorial!
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: Emmons on July 15, 2008, 07:14:00 PM
I like to try a new or more advanced technique on each new knife I make.  After thinking about this knife last night, I decided to try and dovetail the bolsters.  I took the complete bolster and ground down the back edge on the disc sander with the table set at 30 degrees.
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0889.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0890.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0892.jpg)

Next I rough out the handle.  I am using a piece of Walnut from one of my favorite hunting areas in the US.  First flatten on side on the disc sander.  Then I cut the piece in half and cut the approximate angle of the bolster from spine to belly.
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0893.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0894.jpg)

I then grind the front portion that mates with the bolster.  This is done on the disc sander; the table should not be changed from when you ground the bolster.
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0896.jpg)
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: Emmons on July 15, 2008, 07:14:00 PM
Place on the knife with the bolsters in place.  Check the fit between the handle wood and the bolster.  You want this to be very tight.  If it looks good clamp handle on one side and mark out the knife.
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0897.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0898.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0899.jpg)

Using a small hacksaw and the belt/disc sander, I shape the handle material to the outside of the line.  I want to leave it about a 1/8” larger then the finished dimension.  This gives me a little room when I drill the pin holes and epoxy it to the knife.
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0900.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0901.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0902.jpg)

The handle wood is now roughed out.  Set it a side until final assembly.
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0903.jpg)

Now I move on to heat treating the blade.  I try to organize everything first.  I think this is the step that will make or break a good knife.  In the photo below I have everything ready:
Forge, blower, and charcoal
Quenching Oil (Vegetable oil)
Gloves
Magnet
Laser Temperature Gun (optional), I use thing more for checking the oil temperature.
Pliers  
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0908.jpg)
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: Emmons on July 15, 2008, 07:21:00 PM
Once the forged is fired and burning good, I normalize the blade by heating to non-magnetic and allow to air cool.  I do this three times.
    (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0914.jpg)
    (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0915.jpg)

Next I heat the blade to non-magnetic again and quench in 140F degree oil.  I do this with a long rod thru one of the large lightening hole in the handle.  This allows the blade to hang vertical when it is lowered into the oil.
    (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0917.jpg)
    (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0918.jpg)

After the blade is cooled down, I give it a quick wire brushing and clean off the oil.  I then check the hardness with a file.  The file should skate across the blade, if it cut or grabs at all I harden the blade again.  
    (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0919.jpg)
    (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0921.jpg)

Be very careful with the blade at this point as it can shatter if dropped.  The next step is to temper the knife.  I do this in the kitchen over set at 375F degrees (checked with the temperature gun).  I cycle the blade three times hold temperature for one hour each cycle and allowing it to air cool to below 100F degrees between each cycle.  The oven in the photo is in Celsius and show 180.
    (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0923.jpg)

Blade finsh, handle assembly, and final finishing will be done in a day or two.  Thank you for being patient.  Making the build-a-long turned out to be a lot more work then I thought.
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: Lin Rhea on July 15, 2008, 08:25:00 PM
It all looks very good. Anyone could make a knife by following your instructions. Excellent job of teaching. Judging from what you have done so far, it should be a very nice knife. I certainly look forward to seeing the results. Lin
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: Emmons on July 16, 2008, 12:35:00 AM
After the knife has cooled from tempering, I start cleaning it up.  I clamp it down and block sand the whole knife with 150 grit first.
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0932.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0936.jpg)

Next I clamp the knife down at the handle area and start finishing the blade.  First I block sand the ricasso and flat, and then sand the bevel.  Starting with 240 grit sanding progressing to finer and finer grits sanding in one direction (handle to point) until all mark from the previous grit are removed (about 100 strokes per grit).  I sand to 1200 grit now to get a satin finish.
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0940.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0941.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0943.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0944.jpg)

At this point I like to wrap the blade with painters tape to protect it from scratches.
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0946.jpg)
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: Emmons on July 16, 2008, 12:35:00 AM
Now I measure and cut my pins.  For this knife I need two pins 1/8” for the bolster and three 1/4” mosaic pins for the handle.
   (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0904.jpg)
   (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0905.jpg)

Lay all the pieces out and clean with alcohol.
   (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0949.jpg)

Now I start the assembly process.  The first step is to attach the bolster via peening them in place.  I also use a small amount of epoxy on them.
   (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0950.jpg)
   (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0953.jpg)

Clamp one of the handle scales on to the knife, making sure it is tight against the bolster.  Use the pin holes drill in the blade as a guide.  Here I clamped the knife over the center hole and drill the front and back holes.  Place the pins in these holes and more the clamp to drill the center hole.
   (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0954.jpg)
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: Emmons on July 16, 2008, 12:39:00 AM
With two pins thru the drilled scale, locate and clamp the other side.  Then remove the pins and drill using the scale and blade as a guide.
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0955.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0956.jpg)

This is the final step of the knife assembly.  I mix two batches of epoxy, one regular and one mixed with some saw dust from the scales.  Spread the colored epoxy on the surface that mates up against the bolster and use the regular epoxy on the rest of the scales.  Attach them to the blade, then put the pins in with a coat of epoxy and clamp.
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0957.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0958.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0959.jpg)

Thank you everyone complements.  I hope I can finish this up tomorrow.  It will be ready to shape the handle and finish.
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: skullworks on July 16, 2008, 07:06:00 AM
Awesome job...just AWESOME!
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: elk ninja on July 16, 2008, 10:35:00 AM
Great build along!
Mike
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: Emmons on July 16, 2008, 09:27:00 PM
After the epoxy has dried remove the clamps and begin finishing the handle.
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0960.jpg)

I start by removing the excess material and flatten the sides.  I do this with the disc sander, being careful not to heat the blade.
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0963.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0966.jpg)

Now grind the wood down on the spine down to the tang, using the belt sander setup with a slack belt.
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0969.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0970.jpg)

With the excess material removed, I now set the disc sander table at 45 degrees and grind a big chamfer on both sides of the handle.
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0971.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0974.jpg)

Put the knife in a vise and grind the excess wood down to the tang.  Also use the Dremal to chamfer the belly side of the knife.
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0972.jpg)
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: Emmons on July 16, 2008, 09:28:00 PM
Proceed with shaping the handle, I use 80 grit emery clothe to round over all the edges.
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0976.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0978.jpg)

When I have the shape I want, the next step is to block sander down to 1200 grit along the tang.
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0980.jpg)
\\
I finish sand by hand the bolster to 1200 grit and the wood to 320 grit.
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0981.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0982.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0983.jpg)

Next I apply the finish.  I like to use CA glue (super glue).  I do this by placing a bead on the wood then smooth it out with my finger.  Do not stop moving your finger or it will stick to the knife.  I apply 4 coats, sanding with 500 grit between coats.  Then on the fifth coat I wet sand with 1200 grit.
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0984.jpg)

The final step is to remove the painters tape protecting the blade.  Clean off tape residue.  Next I polish the blade and bolster with metal polish.
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0986.jpg)
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: Emmons on July 16, 2008, 09:29:00 PM
Here is the Knife Completed.
  (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_0999.jpg)
  (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_1001.jpg)
   (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_1003.jpg)
  (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_1004.jpg)
  (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_1006.jpg)
  (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_1012.jpg)
  (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_1014.jpg)
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: Emmons on July 16, 2008, 09:31:00 PM
(http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_1016.jpg)

That is it.  I hope you all like it.  Now I just have to make a sheath for it.  For that I will be following the build-a-long Robtattoo did on the cross draw sheath.

James
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: sticshooter on July 16, 2008, 09:42:00 PM
Wow that is saweeet. You need my address.LOL Great post all the way around with a awesome blade to show for it.<><
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: 4runr on July 16, 2008, 10:05:00 PM
Very nice knife, and a very nice build-a-long!
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: skullworks on July 17, 2008, 07:02:00 AM
Very nice! Thanks for an awesome build along that every knifemaker can learn something from!Fantastic job and thanks for taking all the time to show us!!!!!
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: WidowEater on July 17, 2008, 04:04:00 PM
freaking sweeet
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: cdworks on July 17, 2008, 04:34:00 PM
WOW great job!
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: Lin Rhea on July 17, 2008, 07:54:00 PM
A knife anyone would be proud to carry! I especially appreciate your using tools that are readily available to all of us. It shows that technique and knowledge is the largest factor in being able to build a good knife.
                                    Lin
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: Leftieshot on July 17, 2008, 10:41:00 PM
VERY nice job there Chile!!
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: Nosight on July 18, 2008, 01:16:00 AM
Very nice work...
 
Lin is right its not the tools that make the knife.....
 
It be the person behind them

Learned a lot on this tut. shows us beginers one does not need a huge supply of tools to do what we like doing..

Thanks for sharing.......

Later..........Buzz
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: technoman26 on July 18, 2008, 07:49:00 AM
Absolutely stunning knife.  Wish I had the skills to do the same.  Just beautiful.

Thanks for sharing your technique.  The pics were great.

Respectfully -
Rob
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: Montauks on July 18, 2008, 08:01:00 AM
Thanks for posting this tutorial, that was a big job. The knife came out fantastic!

Gene
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: Montauks on July 18, 2008, 11:11:00 AM
James I sent ya an e-mail
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: Emmons on July 18, 2008, 01:31:00 PM
Thank you everyone!!  I'm glad you guys enjoyed the build-a-long.  Lin is correct, you do not need a bunch of special tools to build a knife.  My first knife were made with only a dremal, hand drill, and some files.  But the additional tools make building the knife faster.  I am working on building a 2 X 72 grind with a flat platten and 10" contact wheel.  It will be some time before this is done, but this will speed up the process some more.

Gene-I have not recieved your e-mail, try a PM.
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: Emmons on July 18, 2008, 04:47:00 PM
Not the best photos, but I finished the sheath this afternoon.  Cross draw style made by hot waxing a textured leather.  Breaded leather over the belt loop to spice it up a little.
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_1029.jpg)
 (http://i12.photobucket.com/albums/a222/JPStangs/Knife%20build-a-long/IMG_1028.jpg)

James
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: Over&Under on July 18, 2008, 05:49:00 PM
I am speachless!!!!!

Excellent display indeed!!!!
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: cbarcher on July 20, 2008, 11:52:00 PM
That is a really nice knife great job and I love the sheath too.
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: Oliverstacy on July 28, 2008, 11:14:00 PM
That is amazing...there is a lot of work to a custom knife.  No wonder they cost so much.

Josh
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: joemarty on July 31, 2008, 11:31:00 PM
awsome job thanks.
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: gregg dudley on August 01, 2008, 09:34:00 AM
Very well done.  I enjoyed that a lot.  Thanks!
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: Toecutter on August 02, 2008, 10:17:00 AM
Awesome tutorial!!  Thanks for taking the time to post.
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: Frank on August 30, 2008, 10:58:00 PM
ttt
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: drewsbow on January 24, 2009, 04:25:00 PM
I thought this was worth going around again   :thumbsup:    :clapper:
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: prarieboy on January 24, 2009, 07:43:00 PM
YOU are a true craftsman thanks for sharing  :thumbsup:    :notworthy:
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: Izzy on January 24, 2009, 08:38:00 PM
Unbelievable.Very informative and awesome results.You have inspired me to make a file knife.I dug a few out of my toolbox already.Thank you.                

                                   Izzy
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: 2Knives on January 24, 2009, 09:47:00 PM
I keep looking back at this tutorial to get ideas.
I've got 2 files in a can of wood ashes right now...we'll see how it works out.
If my shop wasn't -5 degrees I'd be out there right now.
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: pintail_drake2004 on January 24, 2009, 09:50:00 PM
how do ya make that jig to cut the bevel?
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: SoNevada Archer on January 25, 2009, 02:05:00 AM
Very nice!  :thumbsup:
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: d. ward on January 25, 2009, 07:57:00 AM
Outstanding work very nice....bd
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: Nosight on January 25, 2009, 12:24:00 PM
This is a great tut IMHO. Each time I read this one alittle more info falls into the cracks and makes building a blade that much easyer.

This is one that should be saved on a perminent basis. Again IMHO

Have read this five times and am learning every time

Thank you for taking the time and giving all of the info to us.

Thanks again

Later.......Buzz
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: Bryant Hollinger on January 26, 2009, 11:00:00 PM
This post encouraged me to make my first knife.
I am now on number 6 or 7. You are one of the ones that are responsible for this addiction!

Thanks!  :scared:    :scared:
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: Phoenix 1967 on February 14, 2009, 09:44:00 PM
Truly professional job man! Excellent!
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: Hartlines on February 16, 2009, 12:12:00 PM
Truly,a fine piece of art!!
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: kbaknife on February 16, 2009, 12:32:00 PM
Quote
Originally posted by Lin Rhea:
"..............technique and knowledge is the largest factor in being able to build a good knife." Lin Rhea.
                                    Lin
I think that should be on a T-Shirt!
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: David Yukon on December 12, 2011, 02:45:00 PM
Great tutorial! thank you for taking the time!
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: GabeO on December 12, 2011, 04:32:00 PM
do you have more pics on your bevel guide would like to make one
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: Cruiser78 on December 12, 2011, 06:46:00 PM
Quote
Originally posted by GabeO:
do you have more pics on your bevel guide would like to make one
X2
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: fish n chicks on December 12, 2011, 10:00:00 PM
Thanks for bringing this back to the top Yukon. I'd never of found it.

Amazing tutorial.
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: mater on December 13, 2011, 01:11:00 PM
Thanks for your time and effort. Ive enjoyed scrolling over this.
  Mark
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: Emmons on December 13, 2011, 05:43:00 PM
Thank you guys,

I am sorry I do not have any photos of the jig as I have upgraded to a grinder and no longer file in my bevels.  If you look at a Lansky knife sharpener you will get the idea, just on a larger scale.

James
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: Rusty Snuffers on December 16, 2011, 02:01:00 PM
This is fantastic.  Definitely something I will try in the near future.

Hey admins: Sticky this post!   :thumbsup:

Rusty
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: TrueNorth on April 20, 2014, 08:54:00 AM
I love this post and continually reread it ,, thank you for a great tutorial
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: KSCATTRAPR on April 20, 2014, 10:14:00 AM
Awesome knife, thanks for sharing this with us.
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: Antlerhog on May 04, 2014, 07:06:00 PM
Very informative. Great job!

Jay
Title: Re: File to Knife Build-a-long (lots of pics) ****COMPLETED****
Post by: Tyler2045 on June 19, 2014, 09:22:00 PM
Hey can get this pinned it is great for beginers