Introduction: Folding Knife From an Old File (w/ Basic Tools)
This Instructable is (not!) sponsored by all of those useless, old, rusted files that are wasting your precious pegboard space.
Why not turn them into knives?
I recently built my own Homemade Drill-Powered Knife Sharpener, so I thought I'd try making my first knife. I thought I could make it from a really old file that I've never used, because its steel is is probably hard enough to hold a good edge.
I don't have any of those fancy metal-working tools, so I tried making it with the basic tools that I have.
Let's get started!
*Pssst! Don't forget to check out more info about the giveaway in the comments!
Step 1: What You'll Need
Hardware & Materials:
Folding File
Chemicals & Adhesives:
Water (Coolant)
Tools (+Attachments):
Wire Brush
Vise
Dremel Sanding Stone/Drum
Abrasive Dremel Cutting Wheel
Permanent Marker
Electric/Power Tools:
6-in-1 Woodworking Machine (It contains the Mini Bench-Grinder)
Drill-Powered Tool/Knife Sharpener
Dremel
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Why: I need a knife!
Recommended Safety Equipment: Earmuffs, Respirator, Safety Goggles,
Cost (for me): FREE!
Difficulty: Pretty Hard
Approximate Time: ~3 Hours
Step 2: Choose Your File
Choose the file that you want to ruin! This should be an old file that you rarely use. Preferably one that is slightly wrecked.
I used a really old folding file that was made in England.
Step 3: Clean the File
My preferred tool for cleaning the file was a wire brush. Make sure to scrape only in the direction of the cutting lines of the file to avoid ruining the wire brush.
I made sure to add water, which would help the sawdust fall off.
Step 4: Mark and Grind the Shape of the File
I started by imagining the way that I wanted the knife to look. After that, I used a permanent marker to color over the parts of metal that I wanted to remove.
I secured an abrasive cutting bit in my Dremel, and started cutting, while making sure that the steel stayed cool with water. I didn't allow it to get hotter than the Dremel itself :)
Step 5: Square Up the Grind
I'm probably using the wrong term for this, but I used my mini bench grinder to make the grind totally perpendicular, as if the knife was never sharpened.
I tried it, and the sanding stone that was in my dremel worked well too.
Step 6: Make the Bevel
In order to make a sharp knife, you need to grind a good bevel.
I started by freehanding it with the Dremel, but later realized that it was easier to clamp it in the vise, and move the knife.
Step 7: Polish the Knife, for Making It RAZOR SHARP!
I'm sorry for the awful pictures. My camera can't adjust the brightness when I try showing how shiny it is :(
I used My Homemade Drill-Powered Tool/Knife Sharpener to polish the bevel. BEAUTIFUL! If you'd more instructions on how to use and build it, please click on the orange link.
Step 8: Use It!
Congrats! You've made your first knife!
I finally know how to ruin the balloons that ruined my motto... ;)
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DONE!
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