Online videos and TV shows make it seem as if you can’t make a knife without a forge. They show blacksmiths going back and forth between a giant forge and an anvil, pounding red-hot metal into sharp blades.
But did you know that you can make a knife without a forge?
In this article, we’ll explain how you can make a knife without a forge in 5 easy steps. We’ll also go over some frequently asked questions about forging knives and how you can do it without a forge.
Can You Make a Knife Without a Forge?
It’s possible to make a knife without a forge as long as you start with a pre-hardened and annealed piece of steel. Using pre-hardened steel allows you to skip having to heat treat your knife and go straight into shaping and grinding.
You can either purchase a knife-blank or a billet and cut out whatever shape knife you want with an angle grinder.
For this tutorial, we’ll be using a Damascus steel billet that can be found here on Amazon for less than $40.
How to Make a Knife Without a Forge
Now that you have your pre-hardened steel, it’s time to get started on making the knife.
Here’s what you’ll need:
- An angle grinder with cutting discs
- A belt sander or bench grinder
- A drill and bits
- Sandpaper in various grits
- Knife handle material (wood, antler, etc.)
- Saw for cutting the handle material
Step 1: Cut Out the Knife Blank
The first step is to cut out your knife blank from the pre-hardened steel. Take your angle grinder and, using the cutting discs, trace out the shape of your knife onto the billet. This can be any shape you want!
Once you’ve got the outline marked, start making small cuts until you’ve cut out the blank. You can also use a hacksaw for this step, but an angle grinder is much faster and easier.
Step 2: Grind and Shape the Knife
Now that you have your blank cut out, it’s time to start grinding and shaping the knife. This can be done with either a belt sander, bench grinder, or simply by hand.
Start by grinding down the edges to give them a more knife-like shape. You can also add any details that you want here, such as serrations or divots.
Once you have the basic shape of your knife set, it’s time to start refining the blade. Slowly and carefully grind down each side until it’s as thin as you want it.
Keep in mind that you don’t want to overheat the blade or else it will lose its temper. Take frequent breaks when grinding and use a wet rag to cool off the knife every so often.
Step 3: Drill Holes for Handle Material
Once your knife is shaped, it’s time to drill holes tang of the knife for attaching the handle material. You’ll need a drill and various bits depending on the size of your handle material.
First, mark where you want the holes to go by using a center punch. Then, using a small bit, drill pilot holes in each spot.
Finally, use a larger bit to make sure your handle material fits snugly.
Step 4: Attach the Handle Material
Now that your holes are drilled, it’s time to attach the handle material.
Take whichever type of handle material you’ve chosen (wood, antler, etc.) and cut it to fit your blade shape. Be sure to use a saw that is specifically made for cutting the material.
Once you have your handle shaped, you can attach it to the blade using epoxy, screws, or rivets. Make sure everything is nice and tight, then set it aside to dry.
Step 5: Sharpen and Finish
The final step is to sharpen and finish the knife. Start by using various grits of sandpaper to smooth out the blade. As you move up in grit, it will slowly get sharper and sharper.
When the blade is sharp enough, you can put a few coats of oil on the knife to protect it from rust. If you want an even more polished look, you can use a polishing compound and buff out the blade.
And that’s it! You now have a custom-made knife, all without using a forge.
Frequently Asked Questions
Before I conclude this tutorial, here are a few frequently asked questions you may have about making a knife without a forge.
What type of steel should I use?
Since you won’t be using a forge, you want to choose a steel that’s pre-hardened and the proper thickness for a knife. Many online shops even sell knife blanks already cut into popular knife shapes, or buy a billet and cut it to any shape you desire.
Can I heat-treat a knife without a forge?
There are several methods to heat-treat a knife even if you don’t have a forge. I’ve dabbled with a few and found that heat treating with a torch was the easiest and most reliable method. Other methods include using an oven, charcoal grill, heat treating with wood, and even a gas stovetop.
Should I anneal the steel?
If you start with a piece of pre-hardened steel, it’s not necessary to anneal the steel. Annealing is only needed if you’re working with softer, unhardened steel and wish to get it hard enough for a knife blade.
Final Thoughts
Making knives without a forge isn’t as difficult as it seems, but it does take some practice and patience. The most important step is to start with the right type of pre-hardened steel.
You should also be prepared to spend a bit more time shaping and grinding the blade. Besides that, the rest of the steps are fairly straightforward.
Good luck with your project and happy forging!
