Making Kitchen Knives – Part 21 – The Last Six Knives

There is not much to say about these, they are all made from one partially rotten palette. Therefore I do not know precisely what kind of wood it is. I suspect it is birch because one of the boards had still a bit of bark on it, but the palette was obviously made from scraps, so there could be several species involves. So other realistic possibilities are poplar and beech.

Since it was from planks, I had no control over grain direction, but I have at least paired the slabs to the best of my ability so they are of the same species – they varied wildly in coloration – and in three cases, I ended up with pairs where one slab had more interesting grain. And, in those cases, I have given this slab on the right side of the knife, where the signature is.

© Charly, all rights reserved. Click for full size.

© Charly, all rights reserved. Click for full size.

© Charly, all rights reserved. Click for full size.

These three are those with more plain-looking handles, besides rich brown color from the ammonia fuming there is not much to see here. I have no idea why the logo etched so strangely on the second one, it just did. Maybe the metal was a bit dirty so it etched only on the edges, where there is stronger current? I did wipe all blades with acetone, but maybe not enough.

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This one has a nice dark stripe of ever so slightly more decomposed, but still hard, wood running down the middle. The placement of the pins is purely coincidental, at least I do not remember consciously putting the holes exactly into the stripe.

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This one has a knot in the wood. Unfortunately, it is so dark, that I currently cannot make a good photo of it without overexposing everything else. The blade on this one is one of those that curled on the edges, so I had to re-grind it into narrower shape.

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© Charly, all rights reserved. Click for full size.

And lastly a piece with extremely beautiful grain, almost like a burl. This one piece really shows that half-rotten wood is not necessarily only fit for burning.

Making Kitchen Knives – Part 20 – Three Finished Knives

Works on this project are finished, so today I will share three more of the resulting products with a bit of commentary about the lessons learned with each.

First a knife with handle from larch.

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This single piece is one of the biggest reasons why I have lost a lot of time with the finishing of handles. Larch wood, as it turns out, is pretty, but it is really shitty for knife handles. It is softwood, but that would not necessarily be a problem in itself. The problems are two: 1) It is stringy, so it has a tendency to tear-out, burning, and gumming up belts. 2) The late-summer-growth is significantly harder than the spring growth and that causes all kinds of problems when trying to shape it to anything other than a plank.

Further, the ammonia fuming did nearly nothing to it, except perhaps making it a bit darker.

I suspected that it is probably not a very good wood for this purpose, and my suspicion was confirmed. I won’t use this wood anymore unless perhaps stabilized with resin. I only used this one piece because it was a gift by a former colleague, who is in turn the intended recipient of this knife. The result is not ugly, but it is much more work than it is worth.

Next is jatoba.

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© Charly, all rights reserved. Click for full size.

This was commissioned, so this is the only blade that will be sold (for a very moderate price). Part of the order was the etched star on the left side. I am a bit anxious about how the knife will be perceived. This customer too was warned that they cannot expect perfection, because I am still learning, but you never know. If they toss it on my head, I will have to deal with it.

I probably will not bother with treating jatoba with ammonia in the future, not in big chunks. It only makes the wood significantly darker and it is prone to develop cracks in due course, nothing else. It is not ugly – otherwise, I would toss it away – but I personally do not think it is worth the hassle. What untreated jatoba looks like you can see here.

And last today cherry.

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© Charly, all rights reserved. Click for full size.

I am a bit ambiguous about how this turned out.  I love the look of untreated cherry wood (see here) and I was hoping perhaps, that the orange color will become richer and deeper. Instead, it has turned into chocolate brown. Not ugly brown, mind you, but brown all the same. Cherry wood is also very prone to develop cracks, but these two pieces almost miraculously were crack-free, I suspect that the strictly perpendicular and straight grain orientation has played a role (they were split from a log, not cut). I will perhaps do the fuming for cherry in the future for thinner pieces with straight grain to use them as a contrast with untreated cherry for intarsia, spacers, inserts, etc. The wood is a joy to work treated as well as untreated, I would use nothing else if I had enough of it.

I have messed up the etch of the number, you can see the straight line where I have accidentally run with the etching graphite rod over the edge of masking tape. But nobody is going to complain about this, because I am keeping this knife for myself.

There will be one more post with the remaining six knives and then we shall look at the time-analysis.

Magnetic Chuck for Grinding Bevels

You may have noticed my previous iterations on building a chuck to help with grinding consistent bevels on kitchen knives. Well, I had a lot of thoughts about it and I thought I can significantly improve it. And luckily I have managed to buy some raw materials before the shops were closed.

I am not going to write full how-to instructions this time, a few words, and the finished thing must be enough for this time around I was still figuring some things on the fly and there were some issues that did not go as planned. However I will probably make another, smaller one, for shorter blades and if I manage to not mess that up, I will make a full tutorial on that one, with clean pictures and components and so forth.

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Here you can see the face with four magnet batteries up front and a tiny ledge on the bottom to have a reference point for the top of the blade. I have made magnets using the same method as last time, only this time I have glued pieces of aluminum between the faces of the mild steel slabs. The body is made from a square aluminum pipe. I cut openings for the magnets in it and to fill the hollows, I have used squared beech timber. That allowed me to simply glue everything together with epoxy and added a bit heft to the piece. I have also used square pieces of aluminum to glue in the sides of the pipe to get perfect seal all-around against water.

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Setting the angle on the last one was a bit difficult. It was done by means of four screws protruding from the bottom, and if they did not stick out all exactly the same amount, it could wobble during work which is not ideal. And they did catch on the edges of the grinding table. Here you can see the simplest solution to that problem that I could think of. On the back of the chuck are two holes with M6 thread. On these two M6 screws hold a flat aluminum profile through two elongated holes. To adjust the angle I simply loosen the screws, slide the aluminum profile up/down as needed, and tighten them again. Against the last iteration, this has the advantage of full linear contact with the base plate all the time, even on the edges, and also it is much easier to set up.

I am trying to get my ducks in the row again, finishing finally the current batch of kitchen knives and preparing for the next one. I hope the two and a half days that I have spent with making this were well spent. I still have no functioning forge, but I work on that too, and hopefully, I will have something to say about that soon.

Making Kitchen Knives – Part 19 – Two Finished Knives

I have decided to throw the pictures at you piecemeal and not all at once. I want to say a bit about each blade and I think that cramming that all in one post would be counterproductive, it would take too long before I could do it and I might get depressed by writing about all the things I did wrong with every piece all at once. I hope you don’t mind.

Two knives are not only finished already, they are with their owners. I did not get any feedback on their use, because for that was not an opportunity yet, but they were well received, despite their flaws. But, well, they say don’t look a gift knife in the mouth or somesuch…

First, let’s say a bit about this universal kitchen knife for my favorite aunt.

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It is one of the best blades, strong, straight and stiff. Exactly what I was aiming for, capable of cutting leeks as well as melons. The handle is made from black elder (Sambucus nigra) wood.

You can see tiny cracks on the faces. I personally do think they can add a bit of a character to the wood – especially if the wood is partially decayed, as you will see on some of the next blades too – but that is not always the case and sometimes they are just blemishes. From a functional standpoint, they won’t be a problem. They are filled with the boat lacquer and thus sealed and glued shut. Anything that destroys the wood now would destroy it even if it were pristine. But it is something I have to figure out how to prevent. I will probably have to seal the ends with silicone or epoxy glue before pickling the wood in ammonia next time, or make the pieces a lot longer (I did make them longer prior to pickling, but apparently not enough).

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And pickling black elder wood I shall, that one thing is sure. Untreated elder wood is yellowish, but the color is nowhere near this bright and rich. I have always loved yellow color, and I think this canary-yellow looks just beautiful. Unfortunately, I cannot show you untreated wood for comparison here, but I will at some point in the future.

What I do not like are the dark shadows around the pins. They are not burned wood (they are grey-ish, not brown-ish), but maybe they are dirt from polishing that got stuck in the epoxy. I will have to look into this next time and maybe not go on too high grit polish before the lacquering and maybe carefully scrape it instead. The wood is beautiful, hard, has small pores, and is a joy to work, but it dirties easily.

The second presented today is a fish gutting & filleting knife for one of my uncles.

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This was ground from one of the blades that came out curly, but it was my plan to take one of these blades and re-grind it for a fish knife from about November 2019, when my uncle expressed a wish for it. The blade is very thin, flexible, and pointy. It would cut vegetables of course too, but I do not think it is suitable for tackling difficult cabbage.

The handle is made from black locust (Robinia pseudoacacia), and this is one of the woods that had a really strong and a bit surprising reaction to the ammonia. You can see in one of my previous posts that untreated black locust wood is honey-yellow/brown with a greenish tint to it. But it apparently contains a lot of acidic components that react with the ammonia and its color got real funky in the process.

When working it, I thought at first that I am burning the wood, and I was trying to sand it slowly and carefully not to do so. It took me a while to realize that whilst I indeed can burn this wood (it is super-hard), I am not doing it. It just looked that way. My subsequent reaction during the work was somewhat “meh” and I thought I won’t bother with this in future anymore, there is plenty of brown woods out there.

And then I have changed my mind.

© Charly, all rights reserved. Click for full size.

© Charly, all rights reserved. Click for full size.

What you, unfortunately, cannot see in the picture is a sort of tiger’s eye effect the lacquer has brought out in this wood’s grain. It looks iridescent and it changes color from light brown with a golden glint to nearly black depending on the angle you look at it. So I went from ” I won’t bother with pickling this wood again” to “I am going to pickle this in buckets”.

Regarding flaws, this knife suffers from uneven shoulders, and it won’t be able to correct them with exercise. I only noticed when I was etching the logo, that I ground the forward-facing facets on the scales slightly askew. Nothing major, but it is visible with the naked eye.

Slight asymmetries in the handle scales that I have spotted too late are actually a bit of a theme in this batch and it is something that I too will have to try and figure out how to prevent. Eyeballing the things during grinding until my eyes start to water apparently still is not enough.

And that’s it for today.

Making Kitchen Knives – Part 18 – Etching

I did not include this step in the time measurement last time, and neither will I do so this time. It is about 10-15 minutes per blade and the only way to reduce that time would be to forgo it completely. If I only signed the blades with my logo, I would have made a significant improvement actually, but since I have decided to number them too, I am back to square one time-vise.

I wrote about my logo design in the Rondel Dagger series. At that time it was meant to be maybe only a one-time action, but the design has grown on me and I have decided to adopt it as my new maker’s mark for all my wood and metal projects. When working on my first commission, I have built myself a specialized etching electrode that allows me to etch the logo without having to mask the whole blade, prepare big solution baths or construct complicated barriers holding the etching solution in place.

This time around I have further improved on this and for the logo etching itself I have built myself a new stencil, since cutting the logo in adhesive tape each and every time leads to inconsistent results and is time-consuming. I tried to get my hands on photosensitive foil to make a stencil, but I was unable to find any seller in CZ offering one that is not for copper. And then I realized that my mother has an old silicone kitchen pad that she never uses, so I asked if I can destroy it in the name of science. She said yes, so I took it and I cut my logo in a strip cut out of it with a scalpel. It is water repellent, so the etching solution did not want to get in there, but a drop of dish detergent in the etching solution has solved (ahem) that problem.

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However, another problem persisted. Etching stainless steel works differently than etching carbon steel. When etching carbon steel with FeCl3 solution, all you need to do after the etch is to let the solution sit for a few seconds and it turns the inside of the etch black with oxides. For stainless steel this does not happen. You need to change the polarity of the electrodes to deposit a layer of black oxide on stainless steel. In order to do so I had to remove the crocodile clips and switch them between the blade and the electrode several times, which was onerous and annoying.

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I have performed tests on the piece of blade that I nearly ground through, and here you can see the results of various etching parameters. On the left, the two etchings are with five minutes of etching time, which was needlessly long and has led to etching the surrounding area under the stencil too. I found out that one minute is more than enough for this logo and those are the two upper logos in the middle. And as you can see, they are grey, not black, because I did not change the polarity. All the other etches are various iterations of me playing with the polarity and whatnot.

After this experiment I have spent a fruitful afternoon cursing in the workshop building this highly sophistimacated tool from a scrap of plywood, brass sheet metal, copper wire, and some left-overs of speaker cables.

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I can plug my 12 V DC source in the input (on the right) and my crocodile clamps on the output. When the switch is held to the left, the red wire/clamp is the anode and it etches. When the switch is held to the right, the red wire is the cathode and it deposits metal ions (which quickly turn into oxides). And I can flip the polarity fairly quickly, and I can either make the logo entirely black or just the outline, depending on how quickly and how many times I switch the polarity. It was quite fun, although there is still some factor of unpredictability in the outcome that I was not able to figure out.

So I could go etching the blades that were ready and as a bonus I got good use out of the rest of the silicone pad too.

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And it worked really well. The best results I got with 1-minute held at etching current, then 10 seconds depositing current and then 1 minute quickly switching the polarity back and forth. After that I neutralized the remaining acid on the blade with washing soda solution, rinsed it off thoroughly and that was it. I got some teething trouble, etchings on some blades are not perfect, but they are not terrible either, they are all identical in shape and size and after I found the correct way, it took me less than 5 minutes per blade.

Etching the numbers was a different kettle of fish after that, for the numbers are tiny, Glagolitic numbers can be quite funny-looking sometimes and I do not think I can cut stencils for them from 1 mm thick silicone sheet. I might try, but for now I reverted to my old method – scalpel and plastic adhesive tape.

Next time I will show you the actual knives that came out of this. I have to decide whether to make one post presenting them all, or scatter them over several days. I think I will do the latter. Either way, taking pictures will take some time too.

Behold: The Unbender!

As I wrote at the beginning of my making kitchen knives project (oh my, is it over a year already?), the steel bars often need straightening before a knife can be made out of them. The method I used then was not particularly time-consuming, but it was very annoying, with the screws constantly falling off to the ground and me cursing all the time. So I have decided to build a jig to help with the job. And here it is.

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This simple thingie took me a ridiculous amount of time to make. Like, three or four times more than it probably should. It might even have cost me more time to build it than I will ever save by using it, depending on how many knives I will make in the future.

The principle is simple, there are three rollers made from old piping and some ball bearings. Two are fixed to the base plate and one is on a plate sliding on two columns opposite them and center between them. A screw in the center can push the upper roller down between the two stationary ones and thus it can bend steel.

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The use is easy. Put the end of a flat bar between the rollers with the concave side down, tighten the central screw a bit and pull the steel back and forth end-to-end through the rollers (but careful not to pull it out completely, because that would mean starting over). Then check for straightness, eventually tighten the screw a fraction, pull, check again, rinse and repeat until the bar is straight.

It works actually very well. I have straightened all my bar stock in minutes and to a better degree than I was able to achieve previously. But still…

Well, hopefully, the finishing works on the forge will go a bit faster, because without the forge I can’t do squat.

Making Kitchen Knives – Interlude 3 – Knifemakers Do Not Make Mistakes…

…they just make smaller, thinner knives

When polishing the blades, I run with one of them accidentally across the edge of the platen. Literally, in a blink of an eye, I ground it paper-thin in a spot, almost through, and I overheated that tiny spot too.

Instead of simply tossing it, I have decided to re-grind it into a prototype of a small knife for peeling veggies and fruits, like garlic, onions, oranges and similar, and also for cutting small things like radishes. For these tasks, the universal kitchen knife that I was aiming for can be a bit unwieldy and I need to test various knife shapes and sizes anyways, so why waste a perfectly good hardened steel, amirite?

This is the resulting knife. The handle is from black elder (Sambucus nigra), artificially infused with silica. That makes the wood a bit harder and it also changes the color a bit in places, making the grain stand out a little more and with a greenish tint. It looks and works actually a bit like an untreated black locust – go figure.

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It is a nifty little blade that goes well in pair with the one I gave my mother two years ago. ~19 cm overall length, 9 cm blade. So far it works well for intended purposes, we will see if my main tester (my dad) is going to have some remarks or complaints. I think that with a sheath it would be a good pocket knife for mushroom hunting too.

Making Kitchen Knives – Part 17 – Watching the Paint dry

This step was a real bugger this time. Forming the handle before it is assembled onto the tang has its downsides, but it also has its upsides. And they seem to prevail, in comparison to the approach I took this time. It took me a lot of time to get all the handles into shape. Part of the problem was also that I have used woods of different properties and thus I had to adjust my approach several times – something that entirely defeated the purpose of saving time by working in bulk. But I got eventually to the stage when I could impregnate the handles with boat lacquer.

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For some of the woods on display here infusing them with drying oil or buffing with beeswax would be entirely sufficient. For some, it would be much, much better to stabilize them with resin beforehand. But the boat lacquer is the most durable and universally applicable finish I have right now, so I have used that. And to make the work more convenient, I have built myself a little stand to put the blades in to dry.

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Unfortunately, I am not done yet so I do not know how much time I have lost in this step. I only have enough data right now to know for sure that I have lost a lot, maybe even an hour per blade. The reasons for this are several.

First, this step was evaluated as “high hanging fruit” because I knew upfront that saving time here will be difficult. Lacquering is the most labor-intensive wood finish imaginable in this context.

Second, some of the savings in my previous step were not really time savings, it was merely that I have changed the order of operations this time and that moved some of the work time from that step into this one.

Third, I messed up, bigly, several times. I repeated steps tat needed not repeating and in the end, I had to redo the coating for four blades. This is why I do not have full data yet – right now, only 8 knives out of 12 are truly finished. But the purpose of learning was achieved, and I have definitively saved some overall time.

 

Making Kitchen Knives – Part 16 – Human-knife Interface

Last time I did this, I shaped the handle-scales first, then I fumed them wit ammonia and then I glued them onto the knives. This time I have changed the order of doing things, but time comparison should still be possible.

After taking the pieces of wood out of the solution I have left them dry. First for a few days outside, out of direct sunlight and out of the wind, with both end-grain ends covered with plastic to reduce cracking (still insufficient, next time I will have to try something more drastic). After they were dry and stink-free, I put them for a few days into the direct sunlight to dry even more, and then I left them to stabilize in the workshop for a few days. That way the wood should be neither too wet nor too dry and hopefully, it won’t change in size too much.

When I started to polish the pieces to sort them out properly – any markings were taken out by the solution – I could not find the oak pieces anywhere. So I took an offcut that was not in the solution and I polished that a bit and I realized that it is not, in fact, oak, but an especially dirty and grimy piece of black locust. I do not even remember where I got it and why I thought it is oak in the first place…

Anyhoo, after grinding all the pieces to flat and parallel, I drilled the holes for pins, cut all pieces to a rough shape on the bandsaw and I paired them up and I shaped and fully polished the forward-facing facets since those won’t be accessible once the scales are glued on. What I learned here was that I will need some finer scaled drill bits, since different woods react differently and when you drill with a 6 mm drill bit, the resulting hole can be anywhere between 5.5 and 6 mm. And trying to force the 6 mm brass pins through some pieces was a real pain in the nether regions. I have to drill the holes in wood ever so slightly bigger than the intended pin, but whilst 6.5 mm was fine for the softer woods it was almost too much for the harder ones.

The next step was glue-up.

To get as near perfect flat surfaces as I can, I have bought a spray-on glue and I used ti to attach a piece of coarse sandpaper to a granite tile. It worked really well, I have got a very nearly perfect match between the tangs and the scales on all twelve knives, the best result I have got yet for this type of handle construction. But I also managed to get a lot of glue on my hands and I lost the spray nozzle when wiping it off and it took two days before it resurfaced under the shop vacuum. So yeah, not my finest hour and the good came with some bad-ish.

During the glue-up, I have suffered from a common ailment –  the insufficient clamping power syndrome. I had to do it in two stages, gluing six blades in the evening and the remaining six in the morning next day, Which was not too much of a problem this time,  since I was tired and I would have to call it quits anyway, but I will probably need some more clamps or maybe even some thingamajigs for gluing the scales on the tangs more efficiently.

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And this is what I got in the end – a pile of roughly shaped handles attached to the finished blades.

During the subsequent grinding to shape with a 40 grit belt, I still could not do too much to evaluate the real effect of ammonia fuming on these woods, but I did get some inkling of what the results might be already. And let us say that for some of the woods I have preliminarily considered the results promising, for some surprising and for some completely “meh”. More about that when the knives are finished.

This whole step took me approximately 73 minutes per knife, and that is a significant improvement against last time – 38 minutes, 34%.

The last step is polishing the handles up to ~300 grit (already done) and putting on a protective coat of boat lacquer. That will take about a week, an hour or so a day. We shall see how that goes, but that part should be relatively free of any surprises.

YouTube Video: DELIBERATE DESTRUCTION – Film and TV weapons

I found this video to be informative and interesting, as well as very painful to watch. I cannot imagine doing something like this to a knife that I have spent several days making. I would do it if I got paid and the destruction were for a purpose, as it is in this case, but even so – ouchouchouch…

Making Kitchen Knives – Part 15 – Tumble Time!

I was on and off working on this project in February. I have filled my tumbler with very fine sand (one that is used to fill in the spaces between concrete pavement bricks) and walnut shells and I polished the blades with increasing grit belts, then I stuck them into the tumbler for a day or two until I thought I can get the scratches all out after 12 hours evaluation.

It was still more time consuming than I would like to, mostly because many blades were ever so slightly bent, a problem that I really hope to solve with plate quenching in the future. On a bent blade, the concave part gets polished quickly, but the convex is a pain in the ass.

So I progressed slowly and at 150 grit I stopped, thinking that the fine sand can take the scratches out in time. It did, however, it took over a week in the tumbler, so next time I will go probably somewhere around 240 or perhaps even 320 grit before going to the tumbler. The blades did have a nice sand-blasted like look to them, so they were de-facto good to go functionally, but I thought they might be still improved by putting them in the tumbler some more. So I did, into a mixture of jeweler’s rouge (Fe2O3 powder) and crushed walnut shells. And I was right, they have now a very nice satin finish that I think is perfect for kitchen knives.

A mirror polish can be a bit sticky, so for kitchen knives, it is not the best option. I will see how sticky this polish is in a bit, but it looks good. Unfortunately, pictures do not give it justice, I won’t even try.

Time-wise, I have spent about 110 minutes per blade with this polishing process to achieve this result. So an improvement of 58%, but with a different look in the end.

Here is the blade line-up from worst to best:

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The first left blade has a slight crack on the edge. Not from the tumbler – that would be possible, but it did not happen – but from the one time where I forgot that the blades are drying on a rug and I took it to wipe my hands. All twelve fell to the floor and this one cracked near the edge and will have to be re-ground to a different shape – I do not know which yet. It was also one of the curly ones and that might have played a role too.

The second blade from the left would be perfectly OK if I did not mess it up. There is a place about 1/3 from the tip where I run accidentally not over the edge of the platen but over the corner. I nearly ground through the blade there, making an unseemly spot where it is paper-thin. I will probably prototype this to a much smaller blade, like a peeling knife. A lesson for the future.

The third and fourth are the remaining two of the curly-wavy blades. One will be re-shaped into a fish gutting/filleting knife for my uncle, one will remain an all-purpose kitchen knife, only with a slightly narrower blade than intended. It will be more similar to the knife I gave my mom and my brother.

The next five blades have a slight bend to the right side that I was unable to straighten out. They will be functional, but cutting straight will be a bit difficult, so not ideal for bigger things like cabbage, but still OK for carrots, leeks and onions, and sausages.

The last three are what I intended to achieve. 25% success rate – a disaster. But I am still learning, so hopefully next batch comes out better.

 

A Knife for my Brother

I did not manage to finish a knife for my brother’s 50 birthday last year, for I nearly hacked off my finger with a hatchet. So I am rectifying the issue this year.

This is the blade that was hardened when I was working on the rondel dagger. It is not a perfect blade, aesthetic-vise. I messed up the polish a few times and I had to eventually stop trying to correct it otherwise the knife would turn into a small razor. It is a good universal kitchen knife, very good cutter, I am just not happy with the surface finish. But it is either this or nothing and this year I want to give my brother a knife I know he wants. He is going to appreciate it even with the flaws.

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I tried to make up for the flaws with the handle, so I have used a piece of partially rotten lilac branch that I have harvested last fall. It is just stunningly beautiful wood and this is probably the prettiest knife handle I have made so far. The wood is rock-hard with tiny pores (lilac is one of those woods that can take 1000 grit polish without dirtying) and would probably hold up well even without the boat lacquer coating. But it was partially rotten, so the outlying regions were not only discolored, but also softer, so I soaked it in boat lacquer to stabilize it. With the coating, it should be near indestructible.

The lilac-colored heartwood will probably age into dark brown over the years, but it might take a really long time since the branch was already several years dead when I cut it off.

© Charly, all rights reserved. Click for full size.

© Charly, all rights reserved. Click for full size.

© Charly, all rights reserved. Click for full size.