How to Make a Knife From an HSS Saw Blade

Knife from HSS Saw Blade

High-speed steel saw blades (HSS) are made of extremely tough and durable modern steel alloys. As a source for knife-making stock, the alloy can provide superior grade metal for the hand-crafter or hobbyist. This article will discusses some of the tools and techniques used in metal-reduction knife crafting, which uses modern power tools and cutting torches rather than the more traditional methods of the forge and anvil.

Things You'll Need

• HSS blade, used Cutting torch Disc grinder with reinforced abrasive discs Dremel tool with cutting discs, points and buffing wheels Belt sander, heavy duty with ceramic abrasive belts Scroll saw Epoxy, JB Weld recommended Small spatula or pallete knife C-clamps Material of your choice for handle, Micarta or Plexiglass recommended Whetstone or Disc Knife Sharpener

Instructions

1. 

   Use a cutting torch to cut a strip of metal from the HSS saw blade. Make it slightly longer and wider than the finished length of your knife blade with the tang. (The tang is the flat metal piece extending from the blade onto which the stock for the handle is fastened.) Rough in the basic contours and shape of the blade. If you do not have access to a cutting torch, a Dremel tool fitted with abrasive cutting discs can be used to cut out blanks for smaller knives- this is a much slower process.

2. 

   Grind the roughed-out blank down further, to the shape of blade you have planned using a disc grinder fitted with reinforced abrasive discs. A Dremel tool with abrasive discs or points can be used for refining the shape or for more detailed features such as serrated portions, hooks and barbs.

3. Grind the bevel along the cutting edge of the blade using the belt sander. (Ceramic abrasive belts are the most efficient for this purpose.) The bevel should be ground at a 20-degree angle. Metal files can also be used for forming the bevel. The blade can also be polished at this stage using fine-grit belts on the sander, using buffing wheels with the Dremel tool, or by hand with emery paper.

4. 

   Roughen the surface of the tang using the Dremel tool and abrasive discs, making crisscross diagonal scratches. (The rough surface will allow the epoxy to adhere more thoroughly)

5. 

   Trace the shape of the tang on your handle material. Cut out the two side shapes using the scroll saw, but leave a small bit of overlapping excess, which will allow for slight mistakes in the cutting process. (The excess will be ground off after the epoxy sets up.)

6. Mix the epoxy following the manufacturer's instructions and apply it evenly to the corresponding sides of the handle material using a spatula or palette knife. Clamp the handle material in place on the tang and check that the handle pieces are aligned and centered properly. Carefully wipe off any excess epoxy that may have overflown the edges. Allow the epoxy adequate time to set, per the manufacturer's recommendations.

7. 

   Grind the slightly overlapping excess material off the edges of the handle. Use the Dremel tool for the final stages of finishing and polishing. Sharpen the cutting edge with a whetstone or disc-array sharpener. Your sleek, tough knife is ready for service.

Tips & Warnings

• Use proper safety precautions using power tools and cutting torches. Ensure that you have the proper training and experience with the tools and operating procedures. Always wear protective safety gear, including safety goggles or glasses, heavy workman's gloves and shop aprons. Work only in well ventilated areas. Always have fire extinguishing equipment close at hand when working with torches.