19/07/2016

DamascusChef'sKnifeWIP

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DamascusChef'sKnifeWIP

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#1

10182010, 01:23PM

JMJones
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DamascusChef'sKnifeWIP
Iamarelativelynewmaker(lessthan
twoyears,veryparttime)andhave
gainedmuchofmyknifemaking
knowledgefromthissiteandmore
specificallysomeoftheWIPthreadsthat
havebeenposted.Ihavedecidedtodoa
workinprogressonmythirdDamascus
kitchen/chefknife.Hopefullysomeonecan
learnsomethingfrommypicsandIcan
getsomefeedback,tipsortricksby
showinghowIdothingstomore
experiencedmakers.Iworkaloneinmy
garagesoIdonthaveanyactionshotsbut
Iwillbrieflydescribeeachstepaswego.
Hereisthestartingsteel.Thelongbars
are1084thatis1.25incheswideand1/8
thick.Theothersteelis15n20thatis.065 ADVERTISEMENT
thickand1.25widefromawellknown
SteelBaron.

HereismyKMGwitha4inchwheeland
blazebeltthatIamgoingtoremovethe
millscall

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Steelmostlycleanedupandreadytobe
cuttolength.

Hereisthesteelcuttolength

Andalternatingsticksof1084and15n20
oneofthemiddlebarsisleftlongerin
ordertohavemorespacetoweldahandle
toit.Ihavenottriedthisbeforebutwe
willseehowitworks.

Shotofmywirefeedwelderattheready

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Hereisthebillettackweldedtogetherat
theendsanddownthemiddle

Apieceofangleironusedforthehandleis
weldedonaswell

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Iwetthebilletwithkeroseneandcoat
with20Muleteamborax.Iwillfluxit
againwhenitgetshotterbutfigurehaving
itcompletelycoveredasitwarmsinthe
forgecanthurt.

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Intothefire

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#2

10182010, 03:22PM

xaman
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Greatpictures.Thanksfordoingthis,thiswillbefuntowatchunfold...

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#3

10182010, 05:59PM

JMJones
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Nearingweldingtemps.Thebilletturnsabrightyellowandwhenremovedfromthe
forgeitfluxsmokes.Ihavetriedweldingwithaventureforgethatdoesnotgethot
enoughconsistentlyandalsowithcoalwithmixedresults.Iswitchedtoablownair
forgefromUncleAlandeverythinggotaloteasierandfaster.

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AfterthebilletisniceandyellowIstillletitsoakforseveralminutestoensurethe
insideisuptotemp.Itisthenbroughttothehydraulicpressandsqueezedwithflat
diestomakethefirstweld.

Hereisthebilletafterafewheatsandpresses.Iamforgingitoutabitinorderto
makesuretheweldsaregood.

IamgoingtobemakingaWspatternwiththeDamascus.Ihaveflippedit90degrees
andampressingonthesidesofthebillets.ThisprocesscausestheWseffectthatyou
willseeinanupcomingpic.
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Tobehonest,Igotalittlecarriedawaywithforgingitdownandendedupwiththis
longbar.Thistookwaytoolongbecauseonlyabout10inchescanbeintheforge
chamberatatime,soIspentmoretimeheatingcooledsteelthannecessary.There
wasprobablyanhourorsoofforgingbetweenthispicandthepreviouspic.Ididsee
JasonKnightcutabilletinhalfsothatthereweretwoshorterbilletsintheforge
insteadofonelongonehangingouttheside.Iwilldothisonthenextstack.

Hereisthebarwiththescalegroundoff.

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Hereisthebarthatiscutinto7equalsections,theeightsectionhadasplit,soI
figuredIwouldjustremoveitnowinsteadoftryingtoreweldthesplit.Ishouldhave
plentyofsteelforthisknifeanyway.

Thisistwoofthesevenbarswithalightetchtoshowthewseffect.Itdoesnotlook
likemuchnowbutafteradditionalstackinganddrawingitwillproduceamore
interestingpattern.

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#4

10182010, 10:50PM

Kainume
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IreallylovewatchingWIPthreads,seeingalltheprocessesthatgointocreatinga
customknife(especiallydamascus)isincrediblyinterestingandexcitingaswell.
Lookingforwardtotheendresult!Thanksforbringingus(me)along

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#5

10192010, 05:57AM

JMJones
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Herethebarsarerestacked,tackweldedtogetherandfluxed.

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Nexttheyareforgeweldedtogether

Thebarisnowdrawnoutuntilitistoolongtoallstayintheforge.Icutitintwoand
weldahandletotheotherbar.Thisstepsavedatremendousamountoftimeand
propane.

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Herearethetwobarsforgedtothedesiredsize.Ididnotmakethecutrightinthe
middlewhensplittingthemsoonewaslongerthantheother.Tomakethemthesame
width,Iusedabarthathadcooledtoactasapressstopwhileforgingthesecondbar.

Hereismysetupforgrindingoffthescale.Iprefertodothisoutsidebecausethe
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anglegrindersendssparkseverywhere.Iuseglasses,gloves,abreathingmaskand
earprotectionduringgrinding.IusedtohavetheguardofthegrinderoffbutdecidedI
wouldrathergiveupsomeeaseofusefortheadditionalsafety.OhandsinceIliketo
dothisoutsideIhavetodragthelegviceandstandintothedriveway.Thenextstepis
cuttingthebilletupandretackweldingit.So,Ihavetodragitbackintothegarageto
useduringwelding.Surewouldbenicetohavetwovices.

Hereistwopicsofthesevenstacksforgeddown

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Heretherearefivebarscuttothesamelengthandreadytobestacked.

Tackedandreadytofluxandgethot.Thiswillgive35layersofws.Whichwillbethe
layercountofthefinalbillet

Thefivebarsforgedtogetheranddrawnout.

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#6

10192010, 06:11AM

xaman
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LookinggoodJohn.

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#7

10192010, 08:01PM

JMJones
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HereIhavestartedtodrawdowntheareathatwillbethehandle.Thebilletisvery
thickatthispointandwewillbedoingaladderpattern,soIwillbecuttinggroovesin
thesideofthebillet,andthenforgingthemflatagain.

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Herethebilletismarkedwithmarkerandarulertogivemelinestogrindto.The
patternisoneoffontheothersidesothatIamnotcuttingagroveinthesameplace
onbothsides.Thiscausesthegroovestobealternating.

HereisthesetupthatIusetocutinthegroovesfortheladderpattern.Thiswasthe
firsttimeItriedthisandwasfairlyhappywiththeresult.Youcouldalsocutdifferent
widthgrovesbychangingwheelsifyouwanted.

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Hereisashotofthegroovesthathavebeencutintothebillet.

Aviewfromthetop

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AtthispointIrealizedthatIhadburnedasmallholeinmyjeans.Ireallydontknowif
ithappenedduringgrindingorduringsomeofthepreviousforgewelding.OnethingI
havelearnedmakingknivesisthatyouwillprobablyburnholesinyourclothesand
aprons.Whenthishappensitisagoodideatocutoutaroundtheholdtoremovethe
charredcloth.Oncetheclothischarreditwillreignitewiththesmallestofsparks.

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Herethebillethasbeenputbackintotheforgeandpressedflatagain.Iwasnotreally
surewhatthefinaldimensionsofthesteelwouldendup,butitworkedout.Thebaris
aboutinchthickandaround15inches.

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Hereisthetemplateofthechefknifewewillbemaking.Thebladewithbeaboutten
incheswitha15inchoveralllength.Thewidthofthebladeisovertwoinches.ItsBIG.

ThetemplateisunderthebilletsothatyoucanseehowmuchIstillhavetoforgethe
bladewider.Iamgoingtotrytoforgeasevenlyaspossibletoreducethedistortionof
thepattern.

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Hereisthetemplateoverthebladesoyoucanseetherelativesizes.Iamgoingto
forgethehandleareaup,sothatItwillelongatethebilletsothatIwillhaveenough
steelleftattheendtomakeasmallblade.

Thispicshowsthepointgroundinandthehandlesectionforgedclosertoshape.Now
isthetimetoensurethateverythingisstraightbecauseIwillbeusingthegrinderfor
therestoftheshaping.Againthisistoreducethedistortioninthepattern.Movingthe
steelwhenhotwillchangethelookofthefinishedproduct.

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Profiledblade!Thisendsthemajorityofthegruntworkinvolvedwiththeprocessand
nowitistimeforthemoredetailedandfinesseworktomakethisintoafunctioning,
appealingpieceofcutlery.

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#8

10202010, 11:47AM

JMJones
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Ifirstusethe4inchcontactwheelshownbeforewithanoldbelttoremovetheforge
scaleandknockdownanyhighspots.ThenImovebacktotheKMGwiththeflatplaten
installedusingafresh60gritblazebelt.Itistimetostarttheflatgrinding.

Hereisonesideflatground.Itisimportanttokeepeverythingasflatandstraightas
possible.ItisalsoimportantthatImakesurethatthedistaltaperinthebladeis
groundinbecauseIdidnotdothatstepwhileforgingtoreducedistortion.

Nowthatthebladeisroughgrounditistimetonormalizewiththekiln.(Ididsome
roughnormalizationheatsafterfinishingforging,butIlikethecontrolofthekilnto
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knowIhittherighttemps.)Iheatthebladeto1550andallowtocooluntilblack,then
1525cooltoblack,andfinally1500cooltoroomtemp.ThenIputitbackintothe
kilnfortwohoursat1200andletthekilnturnoffandslowcooltofurtherstress
relieveanddoasubcriticalanneal.

NowthatthesteelissoftImakesurethateverythingisstraightagain.AtthispointI
canfixanywarps,bendsorbowswithmybarehands.Afteritisstraight,Imark
wherethepinholeswillbeandafewextraholesfortheepoxytogrip.

Thendrilltheholes

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Nextistheheattreat.Iheatthebladeinthekilnat1500degreesandletitsoakfor5
10minutes.Ithenquenchthebladeintoroomtemperatureparks50oil.Afterthe
quenchItemperitinmykitchenovenat300degreeswhilethekilncools.Whenitis
cooledenoughIdo22hourtempersat425degrees.Thekitchenovenisjustasnap
tempersothatthebladedoesnothavetositatroomtempforseveralhourswhilethe
kilncoolstotemperingtemps.Thispicisthebladeafterquenchsittingonmyquench
tank.

Thescalefromtheheattreatisgroundoffandthebladeisreadyforfinalgrinding.

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Theedgeofthebladeisleftthickduringheattreatingsothatdecarbcanbeground
awayandtoassistwithkeepingtheedgestraight.Nowthebladeissharpenedona
slackbeltthatistight.Thisproducesaconvexedge.

Thegrindisthenblendedupthebladeasmuchat1/3thebladewidth.Ibelivethisis
calledaMoranEdgeorMoranGrind.IlearnedthistechniqueatanABShammerinby
watchingBillWigginsdoagrindingdemonstration.Thisallowsforthebladebehindthe
edgetobequitethinandstillhaveenoughstrengthbehindittonotgiveout.Ifitwas
flatgroundtothisthicknesstherewouldnotbeenoughsteelbehindtheedgeto
providestabilityduringhardcuttingtasks.Sincethebladeisheattreated,sharpand
unpolished,thisisthetimetotesttheheattreat.FirstIcutupafewthickcardboard
boxes.Thenhackthrougha2x4andthenensurethatthebladeisstillshavingsharp
andeasilyabletopushcutpaper.ThenIflextheedgeonabrassrodtoensurethatit
doesnotchiporbend.IusuallycuthangingsisalropebutIamoutandneedtoget
more.Ididmakeabunchofcutsthroughropescrapstotestforedgeretention.The
bladepassedalltests.
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Oneofthegreatthingsaboutthisgrindisthatafteryousanditagainlengthwisetothe
bladeitappearsagainlikeaflatgrind.Likethis.

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#9

10202010, 01:30PM

Wulf

Bladesmith,Agitator

JoinDate:
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PartenkirchenGermany
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ReallyenjoyingthisWIP,John.Thanksforposting.Lookingforwardtoseeingthat
pattern!

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D.Wulf,Bladesmith
Instagram@wulfdmaker

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#10

10202010, 02:26PM

RogerP
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OriginallyPostedbyWulf

ReallyenjoyingthisWIP,John.Thanksforposting.Lookingforwardtoseeingthat
pattern!

Dittothat.
Roger

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#11

10202010, 05:42PM

JMJones
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ThanksWulfandRoger,ithasbeencooltoactuallydocumenttheprocessbutIhavea
newfoundrespectformakerslikeBruceBumpandKyleRoyerthathaveproduced
someexcellentWIP's,itisatonofextrawork.

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#12

10202010, 11:03PM
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Dlisch

KnifeMaker/Craftsman/ServiceProvider

JohnthisisagoodWIPthanksforputtingthetimeinIamlookingforwardtoseeing
thedamascus

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ABSmastersmith

http://www.davidlisch.com

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#13

10212010, 06:31AM

peterinct
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OriginallyPostedbyDlisch

JohnthisisagoodWIPthanksforputtingthetimeinIamlookingforwardtoseeingthe
damascus

+1 I'mthoroughlyenjoyingthisthreadtoo...anxiouslyawaitingtoseethepattern
afteretching.
ThanksJohn,
Peter

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#14

10212010, 01:20PM

JMJones
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Nowthatthebladeisgroundto600grit,Iclampittothebaranddoanyfinishhand
sandingwith600gritpaper.

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Nowitistimetostartthehandle.Thetangwillbeslightlytaperedbutnotasmuchas
inasmallerblade.Iwanttoleavesomesteelattheendtohelpcounterbalancethe
longblade.Grovesaregroundinthemiddleofthetangtoreducetheaboutofsteel
thatwillbegroundflatforthetaper.

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Ithenusetheplatenanddiscgrindertotaperandflatten.

Makingthebolsters:Astripiscutfromabarof416stainlesssteelusingmybandsaw.
Thengroundflatandcutinhalf.
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Thetwohalvesaresupergluedtogetherandgroundcompletelyflatonthebackand
shapedonthefront.Shapingasonepieceallowsthebolsterstobeidentical.

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Ithensupergluethebolsterstoonesideofthebladeanddrillthroughthepinholes
alreadyintheblade.Thisinsuresthattheyarelinedup.Thesupergluebondsare
brokenandcleanedupwithacetone.NowIamreadytopinthebolstersandsealthe
jointwithJBweld.

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#15

10212010, 01:22PM

JMJones
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Herethebolstersarepinned,peenedandcutaboutevenwiththespineandlower
portionofthetang.
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Nowthescalesaregluedon.ForthescaledIamusingspaltedmaplethathasbeen
stabilizedbyWSSI.IgotthewoodinablocksoIcuttwoscalesoutandflattenedthem
onthediscgrinder.Ialsomadesurethefrontedgewassandedtomatchupwiththe
backofthebolster.Iamusing15minutecureepoxywithatouchofblackacrylic
paint.

Afterithascuredforseveralhours,holesaredrilledthroughthetangholesand
throughthescale.Theotherscalegluedonandthedrillispushedthroughtheprevious
drilledscaleholesandintothenewlyaffixedscales.

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416stainlesspinsarefittedtoeachholeandglued.Thisdoesnotlookmuchlikea
knifehandlebutoncethegluehasdried,Itakeittothegrinderandgrindthescales
downtothespineoftheblade.

Hereisthehandleafterroughgrinding.

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MywifecameintothegarageandIaskedhertotakeapicofmeworking.Inthisstep
Iamsandingtheandfinalshapingthehandleswithsandpaper.Togettothefinal
polishof600gritonthebolsterstangandwood.

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Ithenetchedmymakersmark.Iwasdisappointedwiththisstepbecauseforthefirst
timeevertheetchcameoutalittleblotchyandtheoffewofthelettersarenotreally
legible.Imadeadeepetchsogrindingitoutwasnotreallyanoptionwithoutchanging
thewholeblade.

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#16

10212010, 01:24PM

JMJones
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Anetchtankfilledwithferricchlorideanddistilledwater.Thebladereadytotakea
dip.Priortoputtingthewholethingintheetchant,Iusednailclearnailpolishtocover
thebolstersandscales.ThisactsasaresistandtheFeClwillnoteatawayatthese
areas.ThebladeisintheFeCLandcheckedandscrubbeddownwith0000steelwool
everyfiveminutesuntilIthinkitisetcheddeepenough.Itisthensprayedwithwindex
withammoniatoneutralizetheacidanddippedinwatertocleanit.Whilestillwetitis
saturatedwithacetoneandallowedtoairdry.Itisgivenalightpolishwith2000grit
paperandverylightlybuffed.

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Iamnotgoingtouseclearnailpolishanymorebecauseitistooeasytomissaspot.
Thatiswhathappedonthebolstersandpins,theacidetchedthemaswell.

Ihadtoresandoutthepittedblackareasandrepolisheverythingupto600grit
again.Hereisthefinishedhandle.

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HereisasampleofwhattheDamascuslookslike.

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IstartedthisprojecttwoweeksagoworkingwheneverIhaveanyfreetime.Ifinished
thebladelastnightandtookthefinalshotsthismorning.Iamworkingoneditingthe
finishedknifepicsandwillpostthemassoonastheyaredone.

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#17

10212010, 05:54PM

BustaCrook

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GreatWIPthreadandthanksabunchfortakingthetimetotakeusalong.Ireally
enjoyeditandyouhaveaniceknifetobeproudof.

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#18

10212010, 06:36PM

JGON

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Awesome.Verynicework.Keepondoingthis,it'sgreatstuff.

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#19

10212010, 07:02PM
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NickWheeler

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DamascusChef'sKnifeWIP

NeatthreadJohn!

Veryhandsomekitchenknife!!!

Youmentionedgettingfeedbackinyourfirstpost.IHIGHLYrecommendyouabandon
yourcurrentmethodofetchingthebladeafterthehandleisgluedon!!!Thatmakesme
cringe,justfortheveryideaofwhathappenedwiththisone.What'sworse,isifthe
Ferricgetsinsidethewood,thelongtermeffectsonthewoodandthesteelunderit
aregoingtobeveryugly.
Ifyoufiteverythingup,includingsomesmallhiddenindexingpinsinthehandle
material...thenyoucanetchtheentireblade...neutralizetheetchingsolution,doyour
finalfinish,THENepoxythe(alreadyshaped/finished)handletogether.Tryingtodoa
finalfinishonabladethatalreadyhasbolstersoraguardaffixedisveryhardtodo.
AnotherthingI'drecommend,isyouclampapieceofbolstermaterialtothebladeand
drilltheholes.Thendothesamewiththeotherside.Thenworkthebolsterpieces
together,butwiththepinsthroughthem.
Hopethisjustcomesoffasthrowingideasyourway,andnotanythingnegative.

NickWho

ThislinkwilltakeyoutothetagalongthreadwhereImadethedamascuscampknife(above)fromSTARTto
FINISH...

http://www.bladeforums.com/forums/showthread.php/808140WheelersSteel*
Stuckinthemetalwithyou

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#20

10212010, 07:46PM

JMJones
RegisteredUser

[QUOTE=NickWheeler8796280]NeatthreadJohn!

JoinDate:
Location:
Posts:

Jul2010
BangorMaine
824

Veryhandsomekitchenknife!!!

AnotherthingI'drecommend,isyouclampapieceofbolstermaterialtothebladeand
drilltheholes.Thendothesamewiththeotherside.Thenworkthebolsterpieces
together,butwiththepinsthroughthem.QUOTE]
Iagreewithdrillingthemseparately.Itriedthiswayasashortcutbutitdidnotreally
workoutthatway.Ittooksomeextramessingwithtogetthefitcorrect.Iwillbe
goingbacktothewayyousuggestfromhereonout.
YouthoughtdippingthebladeintheacidmadeyoucringethinkhowIfelt.Ihave
struggledwithfulltangDamascusbladesduetotheetchingissueonthetang.Ididit
thewayyousuggestedwiththetrialCeraCoatbladefromScotwithsomedifficulties
butIthinkIjustneedsomemorepractice.
Anyandallcommentsaregreatlyappreciated.

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DamascusChef'sKnifeWIP

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