How to Add Serrations to a Pocket Knife

An ordinary straight-cutting edge of a pocket knife can be transformed to a deep-biting saw-toothed edge for slicing through tough, fibrous materials, such as synthetic ropes or the tendons of big game animals, by using the tools and techniques presented in this article.

Difficulty: Moderately Challenging

Instructions

Things You'll Need:

• Permanent marker (Sharpie recommended)
• Ruler with fine-gauge markings
• Vise or clamps
• Dremel or similar high-speed rotary tool
• Cut-off discs and bit
• Grindstone disc bits
• Jeweler's metal files (optional)

1. 
   A Dremel and bits

   Begin by procuring the necessary tools. The most essential one for this procedure is a high-speed rotary tool, such as a Dremel, which is a powerful, hand-held device into which bits with various cutting heads and grinders can be inserted. The main bits used to create the serrations are a cut-off disc and a grindstone disc, pictured here. The best cut-off discs are made of a fiber-reinforced composite that resists chipping and breakage. Choose grindstones with both high hardness and fine abrasive qualities. Select coarse, medium and fine grades of grindstone bits.

2. 
   Mark blade

   Use a permanent marker, such as a Sharpie, and a ruler to mark evenly spaced intervals about one-eighth inches apart.

3. Set the knife and blade securely in a vice or clamping device that will not allow the blade to move or become loose to even the slightest degree.

4. 
   First cuts

   Begin cutting notches with the cut-off disc at the intervals you have marked. Cut slowly and steadily to keep the notches at an even depth and thickness. Make the cuts with fairly straight edges, taking care to keep the disc at a right-angle to the blade's edge.

5. 
   Bevel with grindstone

   Change the bit to a grinding disc and begin to steadily grind arc-shaped recesses at each cut. It is best to grind each recess down only about one-third of the final depth before moving to the next cut, in order to more easily maintain even spacing and allow for periodic adjustments of the shape of the recesses. Consistent size is not critical because a slight amount of irregularity in the serrations will not affect the cutting ability of the blade significantly. But proceeding slowly and methodically will minimize major errors.

6. 
   Finished blade

   Continue the grinding process using finer-grade grindstone bits as you reach the optimal depth and shape of the arc-shaped recesses. Take particular care to shape the projecting sharp points of the serrations where the arcs intersect along the cutting edge. The inside of the arcs should have a smooth bevel down to a sharp edge. An optional finishing technique is to use fine, round jeweler's files to aid in the shaping of the recesses and points.

Tips & Warnings

• Always use safety glasses or goggles whenever operating a Dremel and other grinding and cutting devices. Ensure that the blades are adequately secured in place with powerful clamps or a vise. Grinding and cutting metal can cause it to heat to temperatures that may cause severe burns.

References

• Using High-Speed Rotary Tools