Tag: Stock Removal Techniques

Introduction

Stock removal is a method of crafting blades where material is removed from a solid piece of metal to shape it into a knife. Unlike traditional forging techniques that involve shaping metal through heating and hammering.  Stock removal is great for beginners wanting to make a knife. 

This technique is great for those who want to learn how to make a knife with detail and great great-looking blade with little effort. Making it a popular choice among knife-makers and collectors. Whether you are drawn to knife-making or want to make your own tools.  Or just want to learn more about craftsmanship, learning stock removal techniques is for you!

What Is Stock Removal?

Stock removal is a different way to make knives. You use saws, sanders, and abrasives to remove metal from a steel piece. It is different from forging, where metal is reshaped using heat. Stock removal carves the blade from a flat steel piece. It is faster and easier because you do not need to heat and hammer the metal. You work with ready-made steel pieces. Blacksmithing and stock removal use similar tools and materials. If you like one, you might like learning about the other too.

How Is Stock Removal Done?

If you are new to making knives, stock removal is a great way to start. While there are many ways to make knives, stock removal gives a straightforward and easy entry point for beginners. 

Step-by-Step Process:

• Drawing the Shape: Drawing the Shape: Draw the outline of your blade on paper, then copy it onto the metal with a marker
• Cutting and Smoothing: Use an angle grinder with a cut-off wheel to shape the blade. Make sure it’s securely fastened to avoid any wobbling. Then, smooth the edges with a grinding wheel
• Further Shaping: Use a belt sander with a coarse-grit abrasive to refine the shape of the blade
• Bevelling: Decide on a V or chisel bevel, then use the belt sander to shape the blade edges
• Heat Treatment: Heat the blade until it’s orange-hot, then quench it in warm motor oil. After drilling holes for the handle, heat it again and let it cool slowly
• Tempering: Heat the blade in an oven for two hours at 205 degrees Celsius, then let it cool and remove any imperfections with the belt sander
• Final Bevelling: Attach the handle and apply a finer abrasive to the belt sander to create a second bevel at the desired angle
• Sharpening: Use a fine-grit abrasive to sharpen and polish the blade for optimal cutting

Recommended Tools:

Many knife-makers like  2×72 belt grinders, although other sizes like 1×30 and 2×42 are also used. 

Pros & Cons Of Stock Removal

Pros:

• Accessibility: Stock removal is easier for beginners to learn, allowing them to grasp knife-making basics and improve gradually
• Cost-Effectiveness: It requires fewer specialised tools, making it cheaper for beginners to start making knives
• Versatility: Different types of steel can be used, letting craftsmen experiment with materials and create custom blades
• Precision: Controlled material removal allows for precise blade shapes and dimensions, ensuring consistency in finished products

Cons:

• Waste Generation: It produces a lot of dust and debris, requiring proper ventilation and cleaning to maintain workspace safety
• Time-Consuming for Complex Designs: While good for basic shapes, intricate designs take longer due to precise grinding and shaping
• Material Wastage: Shaping and refining lead to material loss, potentially resulting in higher steel wastage compared to forging
• Limited Texture and Character: Stock removal blades may lack the unique textures and characteristics of forged blades, impacting traditional craftsmanship aesthetics

How To Make A Knife Using The Stock Removal Method

Getting Started

Stock removal is great for beginners because it’s easy to learn. You shape a blade from a flat steel bar using basic tools like grinders and files. Though it takes patience, stock removal lets you fully customise your blade design with precision.

Safety First

Knife-making involves sharp tools, high heat, and potentially dangerous materials. Wear proper safety gear, work in a well-ventilated space, and stay alert. Keeping your workshop clean is crucial for efficiency and preventing accidents.

Tools And Materials You Will Need

Crafting a knife demands a variety of tools, ranging from basic to specialised equipment. Here is a comprehensive breakdown:

Safety Gear:

• Safety goggles: Protect your eyes from sparks, dust, and debris
• Hearing protection: Reduce noise from power tools
• Dust mask or respirator: Guard against inhaling harmful particles
• Gloves: Protect your hands from cuts and burns

Workshop Setup:

• Well-ventilated workspace: Minimise toxic fumes for safe breathing
• Well-lit working area: Good visibility for better workmanship and safety
• Sturdy workbench or table: Provides a stable surface for operations
• Bench vice: Secures materials firmly during tasks

Materials:

• Knife steel blank or stock: Options include carbon steel or Stainless Steel, each with its pros and cons
• Bolster material: Popular choices are brass, copper, and Stainless Steel
• Handle material: Range from traditional woods to modern materials like G-10 or micarta 
• Pins or rivets: Important for attaching the handle securely to the blade

Measuring and Marking:

• Steel ruler or callipers: Gives precise measurements
• Permanent marker or scribe: Marks designs on the steel blank accurately

Cutting and Shaping:

• Angle grinder with cutting wheel: Cuts the basic shape of the knife
• Files: Many types refine the knife’s shape
• Hacksaw or jeweller’s saw: Useful for finer cuts or designs

Grinding and Sanding:

• Belt grinder or bench grinder: Shapes and refines the blade
• Various grit sandpaper: Smooth the blade and handle
• Sanding blocks: Helps in achieving a uniform finish

Drilling and Riveting:

• Drill press or handheld drill: Makes holes in the blade and handle
• Drill bits: Many sizes, especially for pin or rivet holes
• Drill press vice: Clamps the knife hold in place during drilling

Tempering and Heat Treatment:

• Heat source: Oven, forge, or specialised heat treat furnace
• Heat-resistant gloves and tongs: Handles hot blades safely
• Quenching oil: Quickly cool the blade after heating

Handle Finishing:

• Files and rasps: Shape the handle for a comfortable grip
• Sandpaper or sanding belts: Refines the handle’s shape to get a smooth finish
• Epoxy adhesive: Bonds the handle material securely to the knife tang

Assembly and Final Touches:

• Clamps: Holds the handle in place during adhesive curing
• Riveting tools or peening hammer: Secures pins or rivets.Sandpaper: Finalises blade finishing and edge sharpening

Sharpening:

• Sharpening stones: Available in coarse, medium, and fine grits
• Honing guide: Maintains the same angle during sharpening, particularly helpful for beginners
• Stropping compound and leather strop: Achieves a razor-sharp edge

Optional:

• Lanyard hole drilling tools: Add a lanyard hole if desired
• Decorative materials: Enhances the knife’s aesthetic appeal, such as brass or mosaic pins

Maintenance and Care of Tools:

• Regularly clean and inspect tools for wear and tear, sharpen cutting tools, oil moving parts, and store them in a dry place to prevent rust. Proper maintenance ensures longevity and safety

Take The Next Step In Making Your Knife

• Selecting the Steel: Steel choice is crucial for a knife’s performance. Two common types are carbon steel and stainless steel, each with its pros and cons. Carbon steel is easy for beginners and retains a sharp edge but needs maintenance to prevent rust. Stainless steel resists rust but can be harder to sharpen and is often pricier
• Shaping the Blade: Cutting the Blank: Trace the knife’s design onto the steel and cut it out with a grinder
• Heat Treatment: Heat the blade, quench it in oil to harden, then temper it for resilience
• Marking out Bevel: Draw lines for the blade edge, grind the bevel for sharpness, and polish it.
• Tapering Tang: Create depressions in the tang, narrow it gradually, and polish it
• Handle Design: Consider ergonomics, balance, and how it looks when designing the handle to fit the hand comfortably, balance the knife’s weight, and complement the blade
• Bolsters: Square bolsters, drill holes, dovetail the back, shape and polish the front, grind an indent, flatten, clean holes, shorten pins, assemble, peen pins, remove excess material, peen bolster metal, shape bolsters, and clean up dovetails

A Well-Balanced Knife

A balanced knife is an extension of the user’s hand, putting function first and comfort over beauty.

• Why Balance Matters: Balanced knives lessen hand fatigue, give good control, and add precision in cutting tasks
• Factors at Play: Weight distribution between the blade and handle, the choice of materials, and the overall design impact a knife’s balance
• Testing and Tweaking: Balance can be tested by balancing the knife on a finger or table edge. Adjustments, such as material removal or adding, can be done to get the desired balance

Finishing Knife

Once the blade and handle are made and joined, the knife undergoes a final finish. Showing off the knife-makes skills and how he changed metal into a knife. 

• Polish the Spine: The spine, or back, of the knife is polished for a sleek finish, adding beauty and user comfort.
• Shape and Polish the Handle: The handle, where the user grips the knife, is shaped for ergonomic comfort and polished for a smooth, attractive finish
• Add Branding: Brand or personal logos are put on the blade or engraved onto the blade, adding a bit of personality and value
• Sharpen the Blade: An important final step involves honing the blade to a razor-sharp edge using sharpening stones or a honing guide, making it perfect for using

Check this out:

https://www.toolcraft.co.za/blogs/tips-and-techniques/a-beginner-s-guide-to-knife-making-in-south-africa

https://www.andreknives.co.za/index.htm

https://www.andreknives.co.za/index.htm

Know The Difference Between Stock Removal And Forging In Knife-Making

Stock removal and forging are two primary methods for creating knives, each with distinct processes.

• Stock Removal: This method involves cutting, grinding, and shaping a steel piece to form the desired blade. It does not use heat to reshape the metal but removes material to achieve the final form
• Forging: Practised for centuries, forging involves heating the metal until it is malleable, then hammering it into shape on an anvil. Modern bladesmiths often use gas-powered forges for precise temperature control. After shaping, the blade is cooled, reheated, and quenched in oil to harden it.

Sharpening: Both methods end with sharpening the blade to the desired sharpness.

Pros and Cons:

• Stock Removal: Offers efficiency and precision. Ideal for creating uniform and exact designs.
• Forging: Allows for unique designs and textures through hammering and shaping on an anvil. Favoured for creating one-of-a-kind pieces with distinctive patterns

Choosing a Method: Each method attracts different artisans based on their preferences and the types of knives they want to make. Stock removal is often chosen for its precision and ease while forging is preferred for its traditional techniques and unique results.

Conclusion

Stock removal is a fantastic way to make knives. It is easier than forging and uses tools like saws and sanders. Beginners and experts alike love it. You start with a piece of steel and shape it into a knife. It is quick and straightforward, with no need to heat the metal. You simply draw the shape, cut it out, and refine it further. Then, you heat treat it and add a handle. 

Finally, you sharpen it. Stock removal is a fun and practical method for knife-making, offering great precision and control. While it can produce some waste, the overall process is highly efficient and rewarding. It is an excellent choice for beginners and anyone to make their own knives with ease and enjoyment.

People Also Ask

Can you use a Braai as a forge?

You can do blacksmithing on a regular braai grill! All you need is charcoal and a camping airbed inflation fan to blow air. It is a fun way to try blacksmithing at home.

Does an old file make a good knife?

Turning an old file into a knife is a satisfying process that links us to age-old blacksmithing customs. Pick a high-carbon steel file, and clean off any rust and dirt. Next, heat the blade part using a forge or propane torch, and shape the metal on an anvil. It is a hands-on project that brings history to life.

Author: Janice van der Westhuizen