I bought a beautiful blade from Wayland at the North Meet a few weeks ago. I promised to post pictures of it when I finished it. I took some pictures as I made it and thought Id share them here with you all.
The blade has a Damascus back with a forge welded high carbon steel cutting edge. So, it is incredibly sharp with a hard edge and a really strong back that will resist shattering.
The handle is a piece of spalted birch that I have been saving for something special.
I started with the birch by drilling a hole down the length and making it about half an inch longer than the half tang that the blade has. I then put two jigsaw blades side by side in the vice and worked the handle back and forth over them until the drilled hole had become a slot. I kept fitting the tang for size and when it was half an inch or so short, I clamped the blade in the vice and whacked the handle the rest of the way with a mallet.
It was at this point I decided to get the camera and take photos.
Here is the blade fitted into the handle block.
Notice the pencil outline of where I am going to cut.
This is the handle after the first cut. The back and belly of the handle are shaped. The sides are next.
Once again I have marked a cutting line with a pencil and use that as a guide on the bandsaw.
Heres the sides cut to profile.
Im testing it for a basic fit. If it were too large in my hand now would be the time to remove more wood. As it is, it feels fine.
At this point I taped up the blade woth about six layers of masking tape as Im going to be handling the blade as I work on the handle.
I use a power file to round the handle off roughly. It saves loads of time but needs practice to avoid taking too much wood off.
Once I had the rough shape it was over to the dremmel to smooth the surface of the handle some more.
When the knife sits comfortably in my hand, I dont remove any more wood. I use a fine grade of sandpaper then to get rid of any scratches left by the rougher power file. Once it is smooth, I work on it with a dry brillo pad just to make it silky smooth.
At this stage I paint it with linseed oil and go for a cuppa while it soaks in. After half an hour or so, I give it another coat and rub it well in with a rag. Then I remove the masking tape from the blade and look for the first time on my new creation.
I usually whack some beeswax furniture polish on the handle as well once the oil has soaked in then buff it with a duster.
I have a sheath to make for it now and that is a task for later in the week. Ill post a photo of it completed when I have done the sheath.
I think I will keep this one as a working knife. It would be a shame to put it somewhere on display. The work that went into making the blade can only be complimented by putting it to use at every bushcraft opportunity.
Eric
The blade has a Damascus back with a forge welded high carbon steel cutting edge. So, it is incredibly sharp with a hard edge and a really strong back that will resist shattering.
The handle is a piece of spalted birch that I have been saving for something special.
I started with the birch by drilling a hole down the length and making it about half an inch longer than the half tang that the blade has. I then put two jigsaw blades side by side in the vice and worked the handle back and forth over them until the drilled hole had become a slot. I kept fitting the tang for size and when it was half an inch or so short, I clamped the blade in the vice and whacked the handle the rest of the way with a mallet.
It was at this point I decided to get the camera and take photos.
Here is the blade fitted into the handle block.
Notice the pencil outline of where I am going to cut.
This is the handle after the first cut. The back and belly of the handle are shaped. The sides are next.
Once again I have marked a cutting line with a pencil and use that as a guide on the bandsaw.
Heres the sides cut to profile.
Im testing it for a basic fit. If it were too large in my hand now would be the time to remove more wood. As it is, it feels fine.
At this point I taped up the blade woth about six layers of masking tape as Im going to be handling the blade as I work on the handle.
I use a power file to round the handle off roughly. It saves loads of time but needs practice to avoid taking too much wood off.
Once I had the rough shape it was over to the dremmel to smooth the surface of the handle some more.
When the knife sits comfortably in my hand, I dont remove any more wood. I use a fine grade of sandpaper then to get rid of any scratches left by the rougher power file. Once it is smooth, I work on it with a dry brillo pad just to make it silky smooth.
At this stage I paint it with linseed oil and go for a cuppa while it soaks in. After half an hour or so, I give it another coat and rub it well in with a rag. Then I remove the masking tape from the blade and look for the first time on my new creation.
I usually whack some beeswax furniture polish on the handle as well once the oil has soaked in then buff it with a duster.
I have a sheath to make for it now and that is a task for later in the week. Ill post a photo of it completed when I have done the sheath.
I think I will keep this one as a working knife. It would be a shame to put it somewhere on display. The work that went into making the blade can only be complimented by putting it to use at every bushcraft opportunity.
Eric
