Bespoke Knife Set

[bfrd]

I am toying with the idea of making some custom hobby knife sets. The set would include two Japanese Kiridashi style knives (left and right beveled). Two chisels and a wide scraper. They would be made out of Damascus Steel (1095 and 15N20). The general shape will be custom cut with a waterjet. All edges will be single bevels for ease of sharpening. The blades would be hardened and sharpened before delivery.





The picture above is just a rendering based on the vectors I will send to the waterjet vendor. The actual Damascus pattern may not be like the picture. I am buying the steel billets pre-made. Also, keep in mind that these will be extremely sharp hardened steel. The edge will stay reasonably sharp, but will not survive a considerable drop or being used as a pry bar. The tips will absolutely snap off if you apply too much force in the wrong direction. If you look closely at the render, one of them has already snapped just by looking at it. (Ok, that is just a rendering flaw). They will also need to be maintained with sharpening stones.

Since these knives will have to be maintained and handled carefully they will obviously be expensive! The cost of materials and manufacturing is high. I am expecting the pre-shipping cost to be about $200 US. I am not doing this as a business or to make a profit. Even at $200, I would be losing money if I counted my labor costs. I like making things and am willing to share if someone is interested. I just want to see if anyone would be interested in buying such an expensive hobby tool.

[digger303]

Very good project to make your own tools. Dimensions ?
Full length tang ?
A round edged chisel is handy where you use the reverse side for removing detail and square edged blades gouge if not exceedingly careful.

Look forward to the results.

[bfrd]

Unfortunately, I won't be able to make anything curved. I just don't have that level of skill. The knives are about 6 1/4" and the chisels are just ever so slightly longer. I decided against putting scales on any of them, so there is no tang per se. All tools will be a single piece of steel. The billet dimensions are 10" x 2" so I have a little more playing with the handle shapes, but not much. I need to leave some margin for the waterjet to cut properly. If the parts are too close together the water stream will wander.



Opening up the picture above and viewing at 100% is at scale.

[Twokidsnosleep]

Very cool

[digger303]

Unfortunately, I won't be able to make anything curved. I just don't have that level of skill. The knives are about 6 1/4" and the chisels are just ever so slightly longer. I decided against putting scales on any of them, so there is no tang per se. All tools will be a single piece of steel. The billet dimensions are 10" x 2" so I have a little more playing with the handle shapes, but not much. I need to leave some margin for the waterjet to cut properly. If the parts are too close together the water stream will wander.



Opening up the picture above and viewing at 100% is at scale.

Nah not curved. A round shaft of what ever size you prefer then cut at a 40 degree angle ( ? ) just like the flat ones you intend to make.

[bfrd]

Unfortunately, I won't be able to make anything curved. I just don't have that level of skill. The knives are about 6 1/4" and the chisels are just ever so slightly longer. I decided against putting scales on any of them, so there is no tang per se. All tools will be a single piece of steel. The billet dimensions are 10" x 2" so I have a little more playing with the handle shapes, but not much. I need to leave some margin for the waterjet to cut properly. If the parts are too close together the water stream will wander.



Opening up the picture above and viewing at 100% is at scale.

Nah not curved. A round shaft of what ever size you prefer then cut at a 40 degree angle ( ? ) just like the flat ones you intend to make.

I see what you are saying. I just can't get Damascus in rods of a usable diameter. I did find a source for carbide rods that would work.

[bfrd]

I think I decided that before I make any plans for selling anything I will make one set as a sample run and send it to someone for a few months of testing. I have the steel on order for a few sets. I just need to make a jig for grinding in the primary bevel and figure out a repeatable heat treat. This isn't going to be a quick process. This summer is brutal as far as work goes.

[RangerNeil]

I'd certainly be interested in a set. I know UK Border Farce will absolutely screw me on import duties/taxes/handling fees @$200 but I reckon it would be worth it.

[bfrd]

I got the steel billets in last night and will be dropping them off to be cut today.

[Twokidsnosleep]

These blanks look so cool

[digger303]

[Stokesy44]

Too much for me but that does not detract from what I'm sure will be an amazing product.

Daddy needs a new spray booth first

[digger303]

Too much for me but that does not detract from what I'm sure will be an amazing product.

Daddy needs a new spray booth first

Bit much for my pocket too and there is a reason I get get a lot of stuff from the far east and I have a set of chisels.

[bfrd]

I realize that these won't be for everyone. That's why I am only making the 5 sets. I may be able to come down on the price. I was able to trade a set of knives for the water jet cutting services! Now I only need to cover the cost of the stock materials and consumables plus little bit for labor. I have no idea how many sanding belts I will go through. I used up about 6 belts and about 40 small drums on the letter openers I made last year. Granted, these will have far less shaping. I also need to make or buy a jig for grinding in the main bevel. I have also taken @digger303's suggestion and will be including two 1/8" Carbide rods sharpened at one end (4" long) with a 3D printed handle.

[Twokidsnosleep]

Unlike Lando’s deal with Vader, THIS deal just keeps getting better and better !



There is a summer Star Wars marathon on TV we have been watching btw

[BigWall]

Very nice set! I first read is as including a 3D printed candle. I don't know. It could be a good idea.

[RangerNeil]

Deffo interested in a set if they aren't all spoken for.

[bfrd]

Carbide rods are in!


I have a member that is willing to test out the knives. That leaves 2 sets available (assuming the testing shows they work as expected.

[bfrd]

Got them back from cutting.

[RangerNeil]

Looking good.....

[Twokidsnosleep]

I am gonna poke some shite for sure with these

[Stokesy44]

Genius

[bfrd]

Well, I hit a snag. I noticed an error in the smaller chisel. They are not symmetrical. When moving the parts around to make them fit the billet I must have accidentally moved a portion of the design instead of the whole thing. This may not seem like a big deal to some, but for me, this is a deal killer.

I will still finish making them, I just can't in good conscience sell them. On a positive note, I did get bevels ground into the chisels. I just need to re-think my angle jig for grinding the rest.

[digger303]

Well, I hit a snag. I noticed an error in the smaller chisel. They are not symmetrical. When moving the parts around to make them fit the billet I must have accidentally moved a portion of the design instead of the whole thing. This may not seem like a big deal to some, but for me, this is a deal killer.

I will still finish making them, I just can't in good conscience sell them. On a positive note, I did get bevels ground into the chisels. I just need to re-think my angle jig for grinding the rest.

Bummer

[bfrd]

Upon further reflection I think I will be much happier to give these away instead of selling. My skills are improving, but there are going to be small flaws. Here are a couple of the chisels. They are just quickly test etched since I haven’t heat treated them yet.





Those bevels are really difficult for me to keep even.

[digger303]

Yes doing stuff free hand is tricky, probably better if you could clamp them down into even a basic jig.
Mind you when trying to slice plastic off a flat surface the blade cuts a lot easier if the blade approaches at a angle and not straight on. Maybe it's a feature , square edge corners dig in and score the flat surface too.

[bfrd]

Just a small update...

I have made a modification to my jig that should allow me to cut the bevels in the large scraper and the knives. I haven't been able to do much work as the temps here are blistering and everything needs to be done outside. My day job is also kicking my posterior hindquarters. So my mojo is less than nothing at the moment. Haven't even been able to think about models. My bench is covered in bits of sandpaper and Damascus shrapnel (and somewhere an unfinished Sd.Kfz 222)

[digger303]

Just a small update...

I have made a modification to my jig that should allow me to cut the bevels in the large scraper and the knives. I haven't been able to do much work as the temps here are blistering and everything needs to be done outside. My day job is also kicking my posterior hindquarters. So my mojo is less than nothing at the moment. Haven't even been able to think about models. My bench is covered in bits of sandpaper and Damascus shrapnel (and somewhere an unfinished Sd.Kfz 222)

It will all come together when the planets align

[RangerNeil]

Yes doing stuff free hand is tricky, probably better if you could clamp them down into even a basic jig.
Mind you when trying to slice plastic off a flat surface the blade cuts a lot easier if the blade approaches at a angle and not straight on. Maybe it's a feature , square edge corners dig in and score the flat surface too.

Digger has nailed it!! What works for carpentry (where you might be whacking the chisel with a mallet!!) doesn't translate to our hobby.