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Durbin’s Forge Knife Creation Process

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

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