File Knife

It’s funny how some things just seem to find you. I was walking the dogs the other day and came across a free pile. I take that back. Not a free pile. This wasn’t an old cardboard box full of miscellaneous empty jars, ratty romance novels, and unopened yoga VHS tapes. What is was was an old Craftsman standing grinder and a newer Ryobi 4×36 belt sander! Both had signs on them stating that they were free and in working order. I immediately finished the walk and went back with my car.

After setting up the tools in my basement and testing them out I had to decide what to do with them first. I quickly remembered an old small file that I’ve had laying around. I picked it up for a buck at a thrift store a while ago. I had been toying with the idea of making a knife with it and now I had the means.

I first used sharpie to draw the outline on the file and carefully used the grinder to remove material just to the outside of the black line. I made sure to dunk the steel in water between grinds as to not have it overheat. Then I used the belt sander to clean up the profile. I then made a 12 degree jig out of some scrap wood using my table saw to make the blade bevel. I used some blue tape to adhere the file to the wood and then was able to sand down the bevel on one side easily. I simply reversed the file on the jig and taped it again. for the opposite side.

My good buddy Ben over at Hansen Leathercraft sent me home with some Locust wood a while ago and told me it was a great hardwood for woodcarving and handles and such. I used my hatchet to spit a couple of pieces for scales and used the new knife rough out the shape.

I realized that I’m not set up for any sort of heat treat (I’m moving soon to a house with a huge shop so I’ll be building a small forge soon) so drilling pin holes through the hardened steel was a no go. I decided to fake it by adding pins just through the scales to at least give it the look of a finished piece. I used some Loctite five minute epoxy to hold everything together.

I then used many different grits of sandpaper on the scales and then the blade itself to finish it up. I know it’s not going to be the easiest thing to sharpen as it’s really hard steel still but I like it. I dipped the handle in some boiled linseed oil and she really came to life.

Now to just make a sheath!!