Now were ready to begin the “knapping” process. I’m gong to be using a small drum sander in my Foredom™ flexible shaft grinder to create “flakes” in the steel similar to the flakes removed from stone to create a stone blade.
Above, I’ve carefully ground away the “flats” I so diligently placed on the blade with the angle grinder in the previous steps. I’ve created a “lens” shaped contour on the blade, and am now ready to use the sanding drum in my Foredom™.
Above is a side view of the lens shaped blade.
Here, I’ve been carefully sanding in “flake scars” in the steel. Notice how I alternate the length of opposing flake scars, just because I like the visual effect.
Further along grinding in the flake scars.
And, this side finished. Now I have to grind the other side.
Above, the same side with a little cold blue patina, just because I’m impatient to see how it will look when I’m finished.
Above is the other side with the flake scars all ground in.
And, here is the back side blued. Looking good, so far. Keep your fingers crossed…
Above, I’ve drilled holes for the pins that will retain the knife scales.
To keep the weight of this all metal dagger down, I’ll remove as much metal from the handle of the knife as I can without weakening it. Above, I’ve marked where I’m going to begin drilling holes. I’ll join all these holes together with a jeweler’s saw.
Above, all the holes drilled.
And, in the two images above I’ve sawn through the little webs of metal between the holes.
Next
, I’ll harden and temper the blade, then I’ll install the scales, and we’ll be ready to begin engraving. Of course, the really hard part of the process is coming up with an interesting design to engrave!
Thanks for Looking!