Farrier's Rasp Knives:
A viable alternative to for those that want to make a mean field knife that requires no forging. These knives are wicked sharp, and will cut through mild steel! I am able to achieve hair-shaving sharpness, and so far the blades are proving to have good edge holding capability.
Be sure you start out with the best file you can find: I buy these at flea markets, pawn shops, lawn sales or on ebay.
Look For the following:
Black
Diamond
Bellota
Old
Nicholson
Heller
Any
German Brand
Swiss
Brands
Any
OLD American Brand
Here's some files at the start of the process:
First step:
We will grind and shape the knife blank.
Using a side grinder; grind off the surfaces on both sides to knock down most of the file teeth. Use a flat grinding wheel and ensure you take even cuts to ensure a flat surface.
Than make a template and use a cut-off wheel and a grinding wheel to make your knife blank:
The most important thing when working with the files, is not to overheat the steel; thereby loosing the hardness and temper. Take your time and don't overeat the steel. Cooling with water will help.
At this point, I throw the blanks into an oven and temper the steel at 425 degrees for (1) hour. Take 'em out and let air cool, than put them back in the oven at the same temp for another hour, than remove and air cool.
This should give you a good temper, while retaining adequate hardness from the original file.
Next step:
Clean-up the blade shape and grind the bevels with an angle jig and a belt sander.
I like the "scandi / saber" type grind, which brings the bevel up about halfway on the blade.
Mark the centerline first and take your time, make even passes.
Next step:
Spot anneal the handle and lanyard holes. This will allow drilling without a carbide bit, while still retaining hardness of the blade.
Finally:
Make and attach your handles. I am using stabilized oakwood handles, fastened with stainless capscrews and handle furrles.
At this pont you can do a final sharpening with a wet stone and diamond hone.
Sheath Options:
I am making Kydex sheaths, as these offer durability and more options for carry or attachment go your gear.
If you want to go the classic route, a nylon or leather sheath is always viable.
The collection; a work in progress:
These will be available in my store in the near future, so check often!
I am taking custom orders as well, so contact me with your questions.