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CUSTOM KNIFEMAKING Why a Custom Knife? Why is there a desire for a custom-made knife? Fine production knives can be obtained from any of a number of manufacturers at prices that custom makers cannot come close to meeting. And there are so many varieties of production knives offered in various price ranges that a person is almost certain to find a knife to meet his or her needs “off the shelf.” Still, there is a market for custom-made knives. Why is this so? From my experience, the answer to this question is more than just fulfulling a person’s desire to possess something different. My customers tell me, "Make it like this -- so the handle fits my hand." Or, "I need a heavier blade." And some customers want to discuss the advantages and disadvantages of the various knife-making steels, and be able to select a steel that has the properties they desire. And there is still a call for knives of plain old high-carbon steel -- AISI 1095, at times called OF (for "old file"). So, if you need a different size or a different shape, or if the specific qualities of a special steel are for you, you may want to consider having a knife custom made -- for you! Why Should You Know about the Process?
The Making of an Antique Replica Knife. The following photographs show the various stages in making my "antique replica knife." The size and shape of this knife were taken from a photograph of a typical 19th century heavy-duty knife, although minor changes were incorporated for esthetics such as replacing a plain wood handle with India stag.
Overall length of the knife is 15 inches. Figure 1 shows the completed knife.
Figure 1. The Antique Replica Knife
This knife was made of 5/32-inch-thick AISI 1095 high-carbon steel, with brass guard and bolsters, and a handle of India stag. Because of its size, the handle was designed to be assembled in two pieces. First the guard was assembled to the blade; then the rear portion of the handle was installed. This was accomplished by silver soldering the guard to the blade and then welding the handle to the tang – making the entire handle assembly essentially one piece.
Figure 2 shows the handle and the profiled blade prior to grinding. The handle has been cut to fit onto the tang for later welding. Figure 2. Blade and Handle Prior to Assembly Note The reason for the two-piece handle design is that the handle is considerably larger than the slot in the guard, making it otherwise impossible to install the guard. Figures 3 and 4 show how the handle and guard fit on the blade. The space forward of the handle is just one-half the thickness of the guard so that the handle fits into the guard making for a stronger joint. Figure 3. Blade and Handle Assembled Prior to Grinding Figure 4. Blade Handle and Guard Temporarily Assembled Figure 5 shows the final trial assembly prior to silver-soldering, drilling, filing, and welding. The blade has been ground. It is not apparent in the photographs, but the guard edge is ground to an angle of 10 degrees.
Figure 5. Blade after Grinding with Assembled Pieces The bolsters, where they are to meet the stag scales are also ground at a 10-degree angle to form a dovetail joint that serves to permanently secure the stag scales to the handle. Prior to assembly, the stag scales were ground to a matching 10-degree angle. Note
At this stage, the blade was hardened and tempered. Test strips of the same steel used in the knife were included in the heat treatment process for destructive testing. Quenching was accomplished in a brine solution. Testing showed an initial hardness of 67HRC. Test strips at this hardness, although strong, snapped during the bending test. After tempering at 250 degrees and at 225 degrees to relieve stresses, hardness tested at 60 HRC. Test strips were considerably stronger at this hardness, and the steel finally yielded, but did not snap or crack.
Figure 6 shows the assembled pieces after silver soldering the guard and drilling the pin holes in the handle. Prior to installation of the stag scales, the handle was mig welded to the guard. Notice the file work in the handle.
Figure 6. Handle Drilled and Filed with Silver Soldering of Guard Complete The rear bolster is not shown, but was subsequently secured with two brass pins and silver solder at the back of the handle. The front bolster is secured by a brass pin and silver solder.
Figure 7 shows the completed knife. The scales are secured primarily by the dovetails in the bolsters. The decorative pins function mainly to keep the scales from sliding out of the dovetails. There is no epoxy, glue or other compound used in this knife. When suspended by the handle, the blade rings like a tuning fork when lightly struck, indicating a sound and well tempered blade. Note A similar knife can be obtained from Southwest Bladecraft with your choice of materials. However India Stag is in extremely short supply because of an embargo on the material. Click HERE to obtain more information on this knife.
Figure 7. The Completed Knife -- 15 inches overall length
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It's important to me that you know something of the process that goes into the making of a fine knife. The quality in a knife is more than just the final "fit and finish." In two similar knives, one may last a year or two, while another may be handed down for generations. So, while you don’t need to know all of the details, I like you to know that I have the experience to produce knives of quality, and that I will take the time to make a knife that you will not only be proud of, but one that will give you years of service. 
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