Our intention with this book is to show how you can make a high quality knife, using just a few basic hand tools. Once you have read the following pages, you will see that it is not necessary to have a huge workshop, hundreds of dollars’ worth of tools and years of machining experience. Indeed, quite the opposite holds true. You could use your back steps as a bench, and just a few dollars’ worth of files, and still produce quality cutlery.
The following tools are the ones we suggest you use. They would provide you with a basic kit that would enable you to make a wide range of knives. While our suggestions are slightly more than basic, the few extra tools would save you considerable time and effort. The extra dollars would be saved by the improved quality of the work produced.
Bench
The first requirement is a solid work surface. Ideally, a workbench is best. If you lack a bench, any solid flat surface will do. While you could use the kitchen table, you will be producing considerable amounts of steel filings. These are easily swept up from a hard surface, but tend to destroy carpets. Thus you are better working outside than inside. Consequently, the back steps or any other solid structure would be better.
Hacksaw
You will need a method of cutting your steel to size and shape. The best method I have found is to use a hacksaw fitted with a tungsten carbide blade. These blades come in several forms. The first is a standard hacksaw shape, and is ideal for making straight cuts. The second form is known as a ‘rod saw’ and is a wire upon which tungsten carbide crystals have been brazed. These blades will cut curves and intricate shapes, and are the more practical of the two. The American firm Remington produces both blades. They can be purchased at most of the larger hardware stores.
Vise
A bench vise is almost a necessity. While you can work without one, they make it so much easier to hold the work. A 75mm (3 inch) engineer’s vise is ideal. They are not so large as to be cumbersome, and will easily hold all convention knife shapes and sizes.
Files
You will need several types and grades of files. We suggest that you buy the largest flat and half round files that you can find. Try to get bastard files as they quickly remove considerable amounts of metal. (The longer the file, the easier it is to control. Also the longer the file the the more teeth are presented to the work-face per stroke, which means faster cutting).
You will require several finer files for cleaning up the work. Second-cut files will remove the deeper scratches made by the bastard files. Again, buy the largest ones you can find.
For very fine finishing you can use smoothing files. We don’t think these are really necessary, as they tend to clog easily and scratch the work. Also, you can achieve the same effect using abrasive cloth, which is cheaper.
Drills
For some knives you will require drilling facilities. The best tool is a proper bench or pedestal drill. These have a wide range of speeds, and will take drills up to 12mm or more. Since they cost several hundred dollars or more, you would be better to go to a garage for the few holes you might need.
Our second choice is to use a hand drill. These turn at low speeds, and don’t heat the steel. We do not favour power drills. They rotate too quickly. This causes heat build-up, which will harden the steel as you try to drill. You could find that you have started holes that you cannot finish.
The Foreword to the booklet is available here
