Spring 2017 Blade Maker's build thread

Discussion in 'Self-made Gear' started by BigHat, Apr 1, 2017.

  1. BigHat

    BigHat Guide Bushclass I

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    This thread is for all who are signed up in the Blade Maker's Spring 2017 build/swap to start posting their builds.


    Ok fellas, start posting your builds here...
     
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  2. Muleman77

    Muleman77 Hobbyist Hobbyist

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    And so it begins.....An old USA file in the forge

    20170401_131505-1.jpg

    I got this far, this morning. The blades right at 4", 8.5" total length.
    Forged, rough ground, normalized a couple times and drilled. I'll be using two pins and a tube, the rest is weight reduction and epoxy grippers.
    20170401_131647.jpg

    20170401_131703.jpg

    20170401_131714.jpg

    Here's the plan for the scales drawn with a soapstone. Gives the idea anyway. I think I'm probably going to go with manzanita.
    20170401_131859-1.jpg
     
  3. MrFixIt

    MrFixIt Old Jarhead Supporter Bushcraft Friend

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  4. Serkaugh

    Serkaugh Scout

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    Edit 13/04/2017: I'll try to post picture tomorrow. I'll sketch something tomorrow morning. I have an idea of where I want to go. But don't know the size yet.

    Edit 14/04/2017 AM: I've sketched something this morning. Tapatalk wont let me sign in and since its way easier to add picture with tapatalk and no can do, I'll have to upload them to photobucket later and then upload it here

    heres the sketch I've done
    [​IMG]

    Oh and already changed the copper pin for stainless pin. You'll see why

    Edit 14/04/2017 PM

    I tried drilling the hole for my semi-hidden tang, but it didn't went like i wanted.

    How you guys make hidden tang ? I tried drilling horizontaly ( if you're looking at the sketch above) and vertically. But I dont have any file small enough to go smooth the hole.
    I took metal piece and hammer it in place ( same thickness as my blade) worked, but not my drilling hole aren't square to my handle.. rrrgghhh

    I will take this experience as a learning curves..like always!!
    Maybe you guys will come up with an idea I didn't have..


    So there is a picture of my problem. Wasn't very straight, and the fitting wasn't very nice.
    [​IMG]
    [​IMG]


    18/04/2017
    Yesterday I had help from a friends of mine.
    we took care of the problem
    [​IMG]

    There's also a "vestige" of the mistake I made.
    It will look good

    [​IMG]

    22/04/2017
    Had a little time yesterday on the shop

    Before belt grinder, after hardening and tempering.

    [​IMG]



    After 120grit on belt grinder

    [​IMG]


    [​IMG]



    23/04/2017

    After 220 grit:

    [​IMG]

    [​IMG]


    Gluing:

    [​IMG]

    I'll probably work on the handle and change the shape of it. Not sure I like it.

    25/04/2017:
    Oh and I struggle soooo much to keep the point sharp when I sharpen the blade -.-'

    01/05/2017:
    I only need to finish sand the handle and its good to go.

    So, here's my last update:
    13/05/2017:


    Not the sharpest knife I've done but I pretty happy with the result.


    [​IMG]


    [​IMG]


    [​IMG]


    [​IMG]
     
    Last edited: May 13, 2017
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  5. Broke

    Broke Back yard bushcrafter Supporter

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    So, as I have not yet set up my forge, anvil, or really anything... I thought I had better get started on this. Material is a dodge Durango leaf spring. I used a section of the main leaf as it had the longest straight section at about 9.5". I cut off the excess with a 4.5" angle grinder then split the spring down the middle with the same grinder.
    [​IMG]
    I kept soaking it down a nd letting it cool.so as not to overheat it. Hard to do with this thick of material.
    Got it cut down over an hour or so. I am going to clean up the steel, and start bringing it down to a more desirable thickNess. Right now I looking at a 4.75" handle with a 4.5" blade. I am keeping the leaf bolt hole as a choil. Hoping my 1x30 sander shows up quickly. Belts will be here tomorrow. I will do the rough work on my 6x48 sander.

    Started working on evening out the chunk.
    [​IMG]
    Blade is still very very thick. All done for today. I broke my third belt, going to work on it some more tomorrow when I can take a fresh look at my sander.

    Today I was able to do some more shaping. My sander was not cutting it (ahem) as I only have 100 grit belts for it. So I switched to the hand mill aka 4.5 angle grinder.

    Here is where I would up. Roughly shaped, need to clean up the sweep of the clip a bit, grip is about right, I actually dig it a lot.
    [​IMG]
    Nominal thickness is at about .17" will be close to that overall after I true it up, still a few fat spots.

    Spent some more time shaping today. Thickness is at about 1/8" overall and that is where it will stay.
    [​IMG]
    Annealed the blade thoroughly today. Grinding the bevels and such should be much easier.

    Ground in the bevels yesterday, finished the thinning on the handle area, and fixed the warp. Licated the pin holes and lanyard hole, but i cant get anything to cut the steel. Even thoughit was annealed it is still way hard. I am going to heat treat and temper on sunday then affix the slabs when I get home.
    [​IMG]

    [​IMG]
    Then shape the scales
    [​IMG]
    Sharpening now.
    [​IMG]



    Still going pretty well.

    Adam G
     
    Last edited: May 11, 2017
  6. NCSlice

    NCSlice Supporter Supporter

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    I apologize for being late to the party and a big thank you to those who actively participated more than I to keep this going!

    I started with an old Hickory slicer I picked up long ago from a second hand shop. It had a big chip near the tip so it was a prime candidate for this.

    I had other plans initially but then decided to do something a little different than the usual drop point or Kephart I had drawn out. IMG_1896.JPG

    Once cut and ground to the final shape, I cut some scales from leftover palm? (Can't quite remember the name of the wood lol.) from another project I have yet to complete
    IMG_1897.JPG

    Is very close to complete. I have a bit of finish work to do for aesthetics.
    IMG_1898.JPG

    I'll add more pics when I have better light and few more WIP to round it out.

    Now for the sheath!

    ETA:
    Some more WIP...

    I make my hardware with a brass tube from the Lowes hardware "hobby" drawer.
    Pretty sure it's 1/8"
    I tap it with 8-32
    IMG_1957.JPG

    Then I grind the 8-32x3/8 stainless screws. They start to glow and grind down faster once they hit that level. This also darkens them. I like the look.
    IMG_1953.JPG

    This works great for thicker blades. Thinner is a little more challenging but works nicely.
    IMG_1955.JPG

    Got the final handle shape complete.
    IMG_1960.JPG
    IMG_1961.JPG
    I remember now that the scales are Wenge.
    I'm not sure if it's a desirable material or not but it seems pretty sturdy and has a nice pattern. I left them unfinished. I'll let the end user apply BLO, oil, etc to their own liking.

    IMG_1966.JPG
     
    Last edited: Jun 6, 2017
  7. MrFixIt

    MrFixIt Old Jarhead Supporter Bushcraft Friend

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    [​IMG]


    I had a little time in the shop yesterday afternoon. I began by going through my scrounged blade materials. After scrapping the old kitchen knife and band saw blade options, I found a piece of cross cut saw blade...

    Spring2017WIP1.jpg

    I then started to wrack the old brain for a design. I drew up a couple of decent designs and finally decided on this shape...

    Spring2017WIP2.jpg

    The blackened areas will be removed with a grinder, taking care to not to heat the metal.
    That's as far as I got before the wifey pulled me out of the shop.


    image.jpeg

    After about an hour and a half of careful grinding, being mindful not to overheat the steel.

    Spring2017WIP3.jpg

    After slightly annealing the tang where I had the holes for pins marked, I was able to drill through.
    And I also began the edge profile.

    Spring2017WIP5.jpg

    Holes drilled for reduced weight in the tang and better epoxy adhesion.
    Scales (red oak) roughed out.
    Hopefully I'll get a few hours in the shop tonight to glue it all up!

    Spring2017WIP6.jpg

    Checking out the fit of the pins before glue up.

    Spring2017WIP7.jpg

    After the epoxy set for about 48 hours, I began removing excess material from the handle.

    Spring2017WIP9.jpg

    And beginning the contours of the handle shape. It's still too thick so I'll continue to thin it down some.

    Pictures of the finished product. Spring2017WIP10.jpg

    Spring2017WIP11.jpg

    I also did a little phone paper push cut test, no photo of that...:(
     
    Last edited: May 22, 2017
  8. sonofadoublegun

    sonofadoublegun LL&P Supporter

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    Better (almost) late than never!

    I chose to mod an Old Hickory for this build. I zipped over to the local Ace hardware and picked up one of the butcher models. (I forgot to get a picture of it before I started cutting on it, but you all know what I am talking about!)

    I got out the dremel and took a VERY long time cutting off the end of the blade. I then roughed out the shape on my 1x30 HF sander:
    1.jpg

    When that was done, I decided to sand the handle and to give it a wrap with twine down the middle. I also put a notch in the spine for a ferro rod and marked it off for some more metal that I wanted to remove:
    2.jpg

    Close up of the handle wrap. Once the wrap was good and tight, I soaked the twine in super glue, burned off the "hairs" and sanded it a bit to make it less aggressive:
    3.jpg

    Here is a "silhouette" view of the ferro notch, so you can see it better:
    4.jpg

    Afterwards, I put a nice big sharpening choil (to get past the factory plune line) on the blade and gave it a convex primary bevel. Then, I finished her up at 20 degrees on my worksharp. It shaves. :) note - in this picture, the choil is pretty rough. I have since fine-tuned it.
    5.jpg

    Here is a shot in hand after I "tested" it a bit on my workbench:
    6.jpg

    Obligatory wood curls shot:
    7.jpg

    After I was satisfied that it was a good cutter, I gave the edge a final polish and stropped her up:
    8.jpg

    To be honest, this did not come out like I had hoped. I was going to try and make something more like a "poor man's" Bark River Aurora... I got something that looks more like a mini primitive bush knife. Either way, it cuts great, and I think that it will be a good working knife.

    No sheath on this one, but the winner does get a premium folded cardboard blade cover! (lol)

    I hope you found this interesting.

    Best,
    Jamie
     
    Last edited: Apr 29, 2017
  9. prybry

    prybry Scout

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    Already under way...

    IMG_0140.JPG

    IMG_0141.JPG

    IMG_0143.JPG


    IMG_0190.JPG

    IMG_0193.JPG

    Draw knife is ready and I made a nice crooked awl out of the left over spring, so it goes with...
     
    Last edited: May 20, 2017
  10. Paul Foreman

    Paul Foreman Supporter Supporter

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    wish i could forge. but here's an old hickory stock removal knife; let's call it scraps:

    P4060017.jpg

    P4060021.jpg

    P4060023.jpg

    P4060027.jpg

    started as the small butcher knife. angle grinder for the general shape, and belt sanders for grinding the convex edge. peened copper rivet for the front pin, stainless corby for the back pin. scales cut down from the originals. two layers of braided camo hemp for the wrap; top wrap is short of the ends for a bit of a palm swell; hemp finished with epoxy; hickory sealed with coat of polyurethane, then coat of epoxy, sanded back to natural. four inch handle, 3.5-inch blade. very light. very sharp. very handy. sheath to come, as well as another knife of two ...
     
    Last edited: Apr 12, 2017
  11. bladesmith3

    bladesmith3 Supporter Supporter

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    WIP.... well I am finished. :16: my last photo is posted
    440c steel, 3" blade, 4" handle, 7 1/4" length. of course I forgot to drill the holes for the pins and lanyard before heat treat. live and learn. :rolleyes: handle is beautiful ironwood.

    1.jpg 2.jpg 3.jpg 4.jpg 5.jpg
    20170413_202040.jpg 20170413_211315.jpg 20170413_214246.jpg

    [​IMG] [​IMG]
    20170513_094735.jpg
     
    Last edited: May 13, 2017
  12. Red Yeti

    Red Yeti Supporter Supporter Bushclass I

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    OK folks- here's mine

    I started with some old files. I always grab these at yard sales and the like. Use them till they are spent and then forge them into something deserving high carbon. I usually forge blades in small batches. This is just how I like to work. This time I made three parallel.
    files for forging .jpg

    Get them hot in the forge. You can see the little pigtail on this one which is made from the handle of the file
    knife blank in forge.jpg





    I did not take many pictures during forging, but here are three blades rough ground and ready for drilling for pins. Note pigtail on the left.
    blades rough ground.jpg


    Here's the blades after heat treat and tempering

    heat treated blades.jpg

    I made some micarta using burlap
    micarta.jpg

    Here are the handles attached and pinned with some rough shaping. Burlap micarta on the left, some linen micarta on the right:
    Blades pinned.jpg

    EDIT UPDATE : Here are the finished and sharpened finished projects:

    finished scroungers.jpg
    I think the pigtail one is the one I'm offering up.
     
    Last edited: Apr 30, 2017
  13. bladesmith3

    bladesmith3 Supporter Supporter

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    photos tomorrow
     
  14. Paul Foreman

    Paul Foreman Supporter Supporter

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    man, i'm jealous of you forgers ...
     
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  15. Paul Foreman

    Paul Foreman Supporter Supporter

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    Location:
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    here's another one in progress, using the tip from an old hickory butcher knife, seasoned cherry scales, hidden tang:

    P4110002.jpg

    P4110004.jpg

    P4110007.jpg

    P4110008.jpg

    handle is 4.125 inches; iron pins added; blade 2.5 inches; lanyard hole and finish to come ...
     
    Last edited: Apr 12, 2017
  16. Broke

    Broke Back yard bushcrafter Supporter

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    LookING great guys!
     
  17. Serkaugh

    Serkaugh Scout

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    How do you instal the blade in the handle ?!

    An axe ?!
     
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  18. bladesmith3

    bladesmith3 Supporter Supporter

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    more wip pics added
     
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  19. Paul Foreman

    Paul Foreman Supporter Supporter

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    hidden tang, serkaugh: epoxied. pins added now to further secure scales.
     
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  20. Serkaugh

    Serkaugh Scout

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    Updated twice today.
    encountered a problem with my semi hidden tang. help! :/
     
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  21. bladesmith3

    bladesmith3 Supporter Supporter

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    whats the problem?
     
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  22. Paul Foreman

    Paul Foreman Supporter Supporter

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    here is the finished semi-modern otzi type: hidden tang, cherry slabs with hollowed slots for the tang, glued with epoxy (had a void inside one of the slabs that was filled with epoxy/sawdust matrix, can be seen in the joint), blade cut from an old hickory knife and convexed, pins are finishing nails, handle length 4.125 inches, blade 2.5 inches. wood is finished with my normal spoon butter: 50/50 bees wax/food-grade mineral oil:

    P4140013.jpg

    P4140002.jpg

    P4140009.jpg
     
    Last edited: Apr 14, 2017
  23. Serkaugh

    Serkaugh Scout

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    Go to see in my post. I explained. I'll try to add picture if photobucket let me
     
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  24. Broke

    Broke Back yard bushcrafter Supporter

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    Added some weak wip pics...
     
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  25. 1066vik

    1066vik Guide

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    haven't decided which way I'm going yet -- hoof rasp chopper or horseshoe camp/field knife.
    yes, I have started hammering on both.
    pics to come.

    so I started with both a rasp and a horseshoe (because what is rustic without rust?)

    [​IMG]

    the rasp was shaping up REALLY nice
    [​IMG]
    until I got impatient and tried to tap out a warp that showed up during heat treat
    [​IMG]

    so now the pieces will be reforged into 2 different knives at a later time. :(

    OTOH, the horseshoe became 2 blades as well (on purpose this time)
    [​IMG]
    drilled, heat treated, and horse stall mat "scales" added
    [​IMG]
    riveted and shaped (and a little more glue added in a couple of spots)
    [​IMG]

    still need to do some cleanup and make a sheath.
    ( the little patch knife sized blade came from a little horseshoe)

    sheath pattern drawn up
    [​IMG]

    knife and sheath -- all that's left is the final sharpening
    [​IMG]

    knife in sheath:
    [​IMG]
     
    Last edited: May 29, 2017
  26. Paul Foreman

    Paul Foreman Supporter Supporter

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    you guys. some of y'all are ringers ... :)
     
  27. big belly jon

    big belly jon Tracker

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    Iam newer around here where and when is this being held?
    Tia
     
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  28. bladesmith3

    bladesmith3 Supporter Supporter

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    the deadline to sign up for this build was april 1st stay tuned for the next build and swap. you could always start now and have a jump start.
     
  29. Grunt06

    Grunt06 BCUSA Friend Bushcraft Friend Bushclass I

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    Well I got started this weekend at least. Got the file knife in the works. I had to burn a bunch of yard stuff and the county burn ban was lifted! So I started my fire and then once the initial bed of coals was there Threw in the file and kept the fire going for a few hours. Left the file in there, and once completely cool I'll take it out and start shaping. That's the plan as of now, this is the first time I've done this (make a knife and anneal the file) so hopefully I don't screw it up and can get someone a sharp piece of metal. Any suggestions are welcome if you more experienced folks see something wrong with my plan or progress. Pics to come with updates!
     
  30. bladesmith3

    bladesmith3 Supporter Supporter

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    sounds good. I have annealed many files
    BTW I have found that Nicholson files are great steel. look at yard sales ect.
     
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  31. big belly jon

    big belly jon Tracker

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    I appreciate the info brother.
     
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  32. Paul Foreman

    Paul Foreman Supporter Supporter

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    here is the finished neck knife with ambidextrous sheath made by me:

    P4190002.jpg

    P4190003.jpg
     
  33. MrFixIt

    MrFixIt Old Jarhead Supporter Bushcraft Friend

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  34. Broke

    Broke Back yard bushcrafter Supporter

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    More WIP pics added. Getting closer...
    Adam G
     
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  35. MrFixIt

    MrFixIt Old Jarhead Supporter Bushcraft Friend

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    Finally had some time to select the blade material and start on the design.
    Pics added to my "saved" post, #7.

    Comments, criticism and questions welcomed!
     
    Last edited: Apr 21, 2017
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  36. bladesmith3

    bladesmith3 Supporter Supporter

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    the only thing I would have done different is I think I would have reversed the drawing and used the other end of the steel as the blade. but as you know I do like the rustic look a lot. good luck.
     
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  37. MrFixIt

    MrFixIt Old Jarhead Supporter Bushcraft Friend

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    The end I chose for the blade portion had some pretty good rust pitting on the edge.
    I wanted to remove that portion, buy when I get home I'll definitely look at it again.
    Thanks brother!
     
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  38. bladesmith3

    bladesmith3 Supporter Supporter

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    het fixIt.... remember that my opinion should never get in the way of your vision. go with your gut feeling. plus you have the steel in hand and you are by far the best judge of what will make the best
    finished product. you do nice work for sure.
     
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  39. MrFixIt

    MrFixIt Old Jarhead Supporter Bushcraft Friend

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    :dblthumb:
    Thanks for the kind words friend, and you do some awesome work yourself!
     
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  40. Serkaugh

    Serkaugh Scout

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    80% done Updated on post #4
     
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  41. MrFixIt

    MrFixIt Old Jarhead Supporter Bushcraft Friend

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    Another quick update, see post #7 please...
     
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  42. byksm

    byksm Scout

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    im going to call this a multi-functional blade. reamer/awl/scraper... make of it what you will.
    hope you like it.

    i started with a triangle file and random piece of antler.

    did the grind on low speed with a bader.

    [​IMG]

    instead of annealing and a later heat treat, i went straight to tempering.

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    i used pine pitch glue to seal the blade in the handle.
    my first attempt to make pine pitch:
    i used pine sap (obviously), home made charcoal and rabbit pellets for fiber.
    imagine my wifes face when she came out and asked me what i was collecting... i put a pellet in her hand and told her it was rabbit turd.

    [​IMG]

    [​IMG]

    [​IMG]

    did a light patina on the blade and rubbed the whole piece with wax.

    [​IMG]

    have fun.
    -p
     
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  43. Paul Foreman

    Paul Foreman Supporter Supporter

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    fine tool right there ... ^
     
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  44. Serkaugh

    Serkaugh Scout

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    92% done update!!
     
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  45. 138zacvining

    138zacvining Feral bearded man Hobbyist Bushcraft Friend

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    After helping My new neighbor phill feed the horses and a few other little chores around his place and an hour or so of bullshitting . He let me poke around in his barn and shed today . I happened to walk away with some old files . Went ahead made a good size fire and tossed them in to aneal. I'll dig them out of the ash tomorrow and see is they soften up any . IMG_5785.JPG IMG_5806.JPG IMG_5639.JPG IMG_5641.JPG
     
  46. MrFixIt

    MrFixIt Old Jarhead Supporter Bushcraft Friend

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    Another small update in post #7...
    :33:
     
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  47. limabean

    limabean Tracker

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    Pics coming this weekend.
     
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  48. Broke

    Broke Back yard bushcrafter Supporter

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    Little more progress made yesterday.
    Adam G
     
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  49. 1066vik

    1066vik Guide

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    had I been thinking, we could have punched those last week while it was hot.
    you could try heating it back to red in its current state and packing it between a couple layers of the boiler wool overnight - that would give you a better anneal than what we did.
    (slower cooling rate)
     
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  50. Broke

    Broke Back yard bushcrafter Supporter

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    I will try that. Thank you!
     
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