The shadetree knife maker is always looking for blade material. Repurposing metal is always a treat. This blade is over an 1/8 of an inch thick. I am using a 24 inch diameter concrete saw blade. I cut a few small pieces from this blade and heat treated them and took them to work and used a hardness tester to see how effective my heat treat really is. The untouched blade material came in at Rockwell 35. The heat treated material came in at RC55 for hardness. A file is RC60. These will hold an edge nicely.
I cut a chunk of it away with a angle grinder.
This will be a hunting knife with a drop point and a finger guard.
This is a very thick blade.
Next, I heated the blade cherry red and let it cool very slowly to soften the steel. so I could drill holes and grind a bevel and do some file work.
this time I am going to do a "W" pattern on the backbone of the blade. I marked off the spacing with a sharpie.
Then I used a small square file on one side of the blade.
Then turned the blade around and did the other side.
I added a little bluing to bring out the details.
With all the file work done, I heat treated the blade by heating it until it was non magnetic (around 1500F) and then quenched it in 130F salt water. Next I temper it at 400F for one hour. Finally I polish the blade to a mirror finish.
I used curly maple and aluminum pins. I'm calling it "Blonde"
The last step is to make a sheath. I use 7 Oz. Veg. tanned leather and then dye it to the color I want after I sew it.
This knife will has elk slab scales. It was a prize I made for a turkey contest. The blade comes from the same 1/8" thick rusty old concrete saw blade.
For the first step in stock removal, I use a 6 inch bench grinder. I simply clamp a metal stop on the tool rest to keep things consistent
I move it once to get closer to the tip after removing material from higher up on the blade. The tape is to keep me from grinding away the finger guard
I follow up with a belt sander to smooth out the grind marks.
This leaves more of a straight or convex grind which is slightly stronger than the conventional concave grind.
With all the stock removal done and the blade heat treated, I give the blade a going over with 120 grit sandpaper on on orbital sander.
I will use elk antler for the scales.
I split the section in half and sanded them to shape.
I added the antler scales to the knife blade. I used slow cure epoxy and brass pins. I turned out fairly well.
That rusty old blade sure cleans up nice. It was pretty much like a mirror.
Another knife from that same saw blade with alum. bolsters and a Cocbolo handle. I also used homemade mosaic pins to dress it up.