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Acid-Etched 1080 High Carbon Steel Knife

Challenges

- Ensuring consistent heat distribution in a custom-built forge during heat treatment.
- Balancing aesthetic finishing with functional durability.
- Precision alignment of the walnut handle scales with the steel tang.

Results

- Produced a durable and visually striking knife, blending professional-grade functionality with refined aesthetics.
- Achieved a polished yet rugged stonewashed finish, enhancing the blade's character.

Engineering Skills Demonstrated

- Metalworking: Ground bevels with precision using custom jigs and belt sanders.
- Heat Treatment: Hardened and tempered steel using a custom-built mini forge and toaster oven.
- Finishing Techniques: Created an acid-etched, stonewashed blade with a rock tumbler.
- Woodworking: Crafted ergonomic walnut scales, sealed with linseed oil for durability.

Project Summary:

- Crafted a fully functional knife using high-carbon steel, showcasing advanced metalworking techniques, precision heat treatment, and meticulous finishing for durability and aesthetic appeal.

Design and Fabrication Steps:

[1] Blade Construction:

- Cut the blade from 1080 high-carbon steel using a DeWalt angle grinder with a cutoff wheel.
- Ground the bevels using a custom jig on a WEN 4-inch belt sander, ensuring consistent edges.
- Constructed a vortex-style mini forge from firebricks, powered by a high-output blowtorch, to achieve even heating during heat treatment.
- Heat-treated the blade to harden the steel, followed by tempering in a toaster oven to improve toughness.

[2] Finishing:

- Acid-etched the blade in ferric chloride for a darkened, textured surface.
- Tumbled the blade in a homemade rock tumbler with soft-edged aggregate to achieve a stonewashed finish.
- Hand-sanded the blade to a 1000-grit finish before and after etching for enhanced smoothness and sheen.

[3] Handle Construction:

- Fabricated handle scales from 3/8-inch walnut, shaped with a WEN hand file sander for a comfortable grip.
- Secured the scales to the tang with 1/8-inch steel pins and epoxy for structural integrity.
- Sealed the walnut scales with boiled linseed oil for durability and a polished finish.