The Design phase:

1. The blade is drawn out on paper

2. Then it is transferred to a cardboard shape & cut out to see how it functions & fits the hand

3. Next I need to decide if this blade will be forged to shape or made by stock removal

4. Based on method to build the blade, I select the blade steel – some high carbon steel such as O1, 1075, 1095, W1 or others in the pantry

5. Then I select the handle material from my stock of hardwoods.

6. Then I select any liner material to compliment the wood choice

7. Next comes the pin material – solid pin, mosaic, and decide if there is to be a lanyard tube or not

8. If a sheath is needed, I will design the basic sheath style, dye, and thread

9. Final design step is to document the plan for an agenda to follow

 

Profile the Blade by Forging:

1. Select the steel and forge the blade to shape and hammer in all bevels

2. Normalize the blade at least 3 times

3. Anneal it overnight

4. Remove all scale with a grinder

 

Profile the blade by Stock Removal:

1. Select the bar of steel and transfer the pattern to the steel

2. Cut the pattern out and finish grinding the profile

 

Getting ready for & Heat Treating:

1. Locate and drill all pin/lanyard holes – including any guard/bolster arrangements

2. Rough surface grinding and beveling to pre-heat treat dimensions

3. Stamp Maker’s mark on the blade & any other stamp marks planned

4. Heat Treat (Quench) the blade to harden the steel

5. Temper the blade 3 times to make it tough

 

Post Heat Treat:

1. Finish bench grinding all bevels to pre-sharpened state

2. Hand sand the blade

3. Drill, cut, and glue scales/pins for the handle

4. Shape the handle and hand sand before applying oil to seal the wood

5. Design & create a sheath if one is to be made

6. Sharpen the blade

7. Create a Birth Certificate/Document of Origin