from file to knife

[KHalverson]

I do mostly forged blades now .
but here is a fairly simple build along that requires minimal of tools to transform a junk file into a good usable knife.
feel free to substitute tools as you have them.
my goal was to build a knife with only tools that most people here have.

here is my list of tools being used.
safety glasses
cordless drill
tape measure
belt sander
dremel tool
hammer
files
prick punch
sand paper  (various grits)
spring clamp
propane torch
kitchen oven.



here is my intended victim with a sketch of the proposed knife
I chose an old u.s.a made Simonds file
I also use german and Swedish made files .stay away from cheap files!  i.e china and Pakistan.

next step is to cut out intended pattern and trace on the file

[Gus]

Yes Sir, Very Cool!
Looking forward to watching your progress.

Thank You for posting this thread!

Regards,

-gus

[Gus]

Yes Sir, Very Cool!
Looking forward to watching your progress.

Thank You for posting this thread!

Regards,

-gus

[KHalverson]

  next step is to rough cut out the blank using the dremel and cut off wheels
I now use the belt sander to profile the blank to a more refined shape


this is a slow process using only the 3x18 belt sander with a 36 grit belt
I like to do this bare handed so I can feel how hot the blank  gets.
if it gets too hot to hold  dip in water to keep cool.



here is the rough profiled blank  ready to go into the kitchen oven

[koan]

Is it better to soften the file before rough out? Thanks for the biuld-a-long, been wantin to try this for some time now... Brian

[KHalverson]

koan
you could run it thru a temper cycle before shaping.
my plan is to do this build along  using the already hard file  and tempering the cutting back to a more friendly, tougher, non brittle state
hopefully tomorrow I will be showing how to draw back  (anneal) the handle and spine  of the blade.
Kevin

[koan]

Thanks... Brian

[PEARL DRUMS]

Kevin I think its cool your doing this. Need more files? We go through bastards at work like water.

[KHalverson]

PD
thanks.
ive got a pretty good stash but if there good U.S.A made files  I sure would take em.
kevin

[KHalverson]

ok
knowing that the steel used in most quality files tempers out at around 400f.
we will start a little shy of that .
and my kitchen oven tends to run a little hot.
we will set the oven for 350f and let the blank soak for 2 hours



 

[osage outlaw]

This is great stuff right here.  Thank you so much for posting it.

I put a couple of old files in a campfire this past summer to soften them up.  I'll be using your info to finish them up.

[KHalverson]

after a 2 hour temper cycle and cooling its now time to test the hardness.
this is where sharp files come in handy.


the hardness feels pretty good to me.
a sharp file cuts the steel but not easily.

time to lay out and file in the choil
I want the blade to be 3 1/4 long so I mark the choil at 3 1/8

I file in the choil with a sharp chainsaw file
again the steel is pretty darn hard but can be filed.

the next step is to draw back (aneal) the handle and spine of the blade.
for this I use the spring clamp and a cake pan full of water to protect the hardness of the cutting edge.

I now proceed to heat the handle portion of the blank to cherry red with the propane torch and let the heat transfer into the spine of the blade.
I do this 3 times to ensure that the handle portion is soft enough to drill.


after draw back I shape the handle to finished dimensions.
using files and the dremel tool with a 1/2 in sanding drum.


here the bevel is layed out on the blade and where the tough part of this job begins.



filing in the bevels.
I spent at least an hour filing each side.
its tough work even with sharp tools.

[Danzn Bar]

Super great build along.....Love this one,     This is another thing to add to my to do list.  There is just not enough time in the day, weekend to everything I want    Retirement 

DBar

[KHalverson]

ok
bevels are filed in and look pretty good and even.


time to clean up the bevels slightly on the belt sander.

[koan]

Man, thats really lookin good!