Basic Knife Making Process - CRATEX Abrasives

Knife – Oldest Tool Used by Man

We use knives every day, at least in the kitchen, but how many times have you asked yourself if it was possible for people of early civilizations to survive without a knife. Today we use all kinds of knives - paper knives, pocket knives, bread knives, camper and hunting knives, etc. However, a knife made of flint provided food and was a tool for making shelter in the Stone Age. Some say that the invention of the wheel was the most important invention in history, but how did they manage to build the wheel without a cutting tool? The knife was the first handmaking tool that we used to manipulate the world around us.

People used different materials for making knives. At the beginning, it was flint, copper, bronze, iron and, finally, steel. Techniques for making knives also evolved along with the new tools used for knifemaking.

We still have knives with fixed blades and folding knives as before. So, what has changed the most over the years? The material is what changed the most! These days we use sophisticated materials for knife making, like stainless steel, titanium, carbon or ceramics.

Centuries after, a knife is more than just a weapon for hunting animals and plant cultivation. Knife found its way to our tables, we use them daily. Knifemaking became a true art. Knife customization, engraving and adding gemstones is not so rare anymore.

Knifemakers & Making Process

Knifemakers are custom knife manufacturers. Some call them bladesmiths. They build knives out of blade material, usually from steel. This is done by forging. Blade material is heated over high temperature and then shaped with a hammer. After shaping comes grinding, polishing and other blade finishing processes. When the blade is done, it is time to make handles. They are usually made of wood, leather, ivory, micarta, stone etc. which is a harder way to make knives. Hobby knife makers and enthusiasts rarely do forging - instead, they do a stock removal. Below is just a baseline that will give you a clue on how to make a knife. 

Basic Knifemaking Process

1. The most common process of making a knife starts with a knife design. You can draw a knife on a paper or design a full 3D model in CAD. It is up to you. 
2. After designing, you must choose a blade material. It is also important to choose material thickness. You'll find more about choosing blade material in the chapter dedicated to tools.
3. The next step is cutting the steel bar to achieve a knife shape per design. Here you will need vise, drill, grinder, file and saw with blades. Put the drawing onto the steel sheet to make a model. You can do this with a permanent pen. Now place steel into the vise and start cutting the steel according to the model with a hacksaw. If you are skilled enough, you can do this with a grinder or cutting wheel.
4. Afterwards comes grinding to remove excess metal from the blade model. You can do this with a standard file or a belt grinder.
5. Now it is time to finish the edge and make bevel. This is the most important step and a very delicate one, so be patient. Simply draw a line down the middle of the steel where the edge of the blade is going to be, so you can create symmetrical bevels. You can make bevels using a file or a belt grinder. Watch this tutorial if you want to learn how to do it with a belt grinder. YouTube is full of video tutorials like this one. If you are using files, like most hobby knifemakers, try to grind at the same angle between the steel and the file. Be careful not to remove more metal then you should. Once you finish one side, turn the blade and do the same on the other. Most people ruin their previous work in this stage, so take your time. 
6. Drill holes for handle pins. Use a hand or bench drill.
7. Heat treatment – hardening & tempering. Steel needs to be heat treated. You need to harden the blade by heating it on a high temperature and then quench it in the oil to cause a molecular change in the structure. Heat treatment depends on the material and it is technically very demanding. That is the reason many knife makers use services from professional heat treaters.
8. Blade finishing - remove tarnish from heating treatment and other impurities. You can use sandpaper or rubber abrasives to achieve a mirror finish. CRATEX abrasives are the perfect choice for finishing and final touches.
9. Make and attach the handles -  Handles should not just look nice, they must be durable regardless of the temperature, and water resistant. Most used material for handles is wood. First, you'll need to do is to drill pin holes (if you didn’t in step 6). Protect blade with a tape so you don’t cut on it. Clean surface. Attach and glue handles to a knife using epoxy and pins. Cut pins to the right size and put two clamps and let it sit for 12 hours. After that, shape handles using drum sender. In the end, finish and protect wooden handles with gunstock oil.
10. Sharpening the blade –use whetstone or diamond stone. Put the stone on the table and lubricate it with mineral oil. Hold a knife at 17°-20° angle to the stone and start dragging the knife down to the stone with a light pressure.  

IMPORTANT: Protect your eyes, hands and lungs. Always use protective gear.