I have recently taken an interest in watching Ray Mears and Bear Grylls on TV, I have always had an interest in the outdoors camping and wild camping and I do like to cook on a camp fire. So I decided to try my hand at a bit of home bushcrafting. Now what does every bushcrafter need? yup thats right a knife for felling trees and making shelters.
I decided to try and make myself a nice sturdy knife….. This is where things got a bit tricky. What do I need how do I do it etc. Now I do have a bit of knowledge of metalworking from my days at college during my apprenticeship many moons ago so decided to embark on a refresher trip of fact finding. With the help of my good friends youtube and google I soon found a wealth of information to help me on my way.
First of all I selected an old rusty file from my tool box and this was to be the donor metal for my wee project. Then I needed to anneal the hard steel so I could work with it. The BBQ was loaded up with charcoal and the heat treatment began. So after a long time in the BBQ (overnight) I went out to the garden to retrieve my trusty old file. Now that it was suitably softened and suitably cool it was time to drill holes in the handle and use another file to shape the blade. A couple of hours of sweating and swearing later my knife had roughly the shape I wanted. Now the tricky bit. Time to re harden the steel.
This involved the BBQ loads of charcoal and my wife’s hair-dryer to help the forge (BBQ) reach the temperatures required to re harden my knife. Now apparently the correct temperature is when the steel is no longer magnetic so every now and then I would take my knife out and stick a magnet to it, on one of these attempts I managed to vaporise the fingerprints from one of my fingers when my finger tip brushed against the nearly red hot piece of metal! (Not actually as sore as it sounds) Once I got the temperature correct the blade requires quenching in some water to cool it quickly. This now left me with a hard but brittle blade. The next step was to clean up the piece of metal to make it nice and shiny so that I could temper it. I did this by putting it in the oven and keeping an eye on it until it turned a straw colour. This indicates that the blade is now tempered which means hard enough to take an edge but not so brittle that it will shatter!
I sourced a couple of hardwood offcuts to make the handle and this is where things got messy and sore. Whilst cutting the wood to make my knife handle this happened!!!!!

This hurt more than you could imagine
My saw slipped and came to an abrupt halt embedded in my thumb. So thumb in mouth I went to the first aid box and bandaged it up. After about 5 minutes the pain was getting unbearable so I got the wife to take me to A&E to get checked out. The first hospital sent me to another hospital where they cleaned the cut bandaged it up and gave me a tetanus injection. Which made my arm swell up and hurt like a biatch for a few days!! The picture above was taken 3 days after the injury occured. It is now a full week after my injury and my finger is still a bit tender and I can see it being quite a while before it gets back to strength. On insection of the saw afterwards I removed several small pieces of bone from its teeth!!! I really do need to be more careful in future.
However I can now do a limited amount stuff again so decided to complete the job in hand. Luckily for me the wife is away for a few days as I think she would of had a turry murry if she caught me with a saw in my hand again! Thanks to one of my mates who provided me with a rather fetching pair of work gloves I was confident that I would not be repeating the injury. So after much cutting shaping rubbing down I manufactured a nice couple of pieces of wood to glue and pin to my knife. The finished job can be seen below!

It may not be a Ray Mears Woodlore knife or a Rambo survival knife but I am quite delighted with the outcome and the fact it was all done in a very much handmade and simple fashion has impressed me. I have yet to chop any trees down or slay any marauding zombies but I am sure it will function perfectly well for its intended use. My next project will be to source some leather and manufacture a sheath for it. However I think that will have to wait until the thumb is substantially better due to the dexterity I think the job will require. If I remember when I am making the sheath I will try and take photos of the process and not end up in A&E.