Adventure Blade

Turning Scrap into Sharp Art: How to Make Folding Pocket Knives from Scrap

Have you ever looked at an old wrench, a rusty saw blade, or a piece of scrap metal and thought, "Can I turn this into something cool and useful?" Well, you're not alone. Many makers, blacksmiths, and DIY fans have turned scrap metal into beautiful folding pocket knives—right from their home workshops.

In this article, we’ll take a deep dive into how to make folding pocket knives using scrap materials. We’ll walk through the process step-by-step, including what tools you need, how to pick the right scrap, tips for shaping and assembling, and some creative ideas to make your knife one-of-a-kind.

Let’s get started!

1. Why Make a Pocket Knife from Scrap?

Folding pocket knives are handy tools. You can use them for:

Opening boxes
Camping
Cutting rope
Outdoor survival
Everyday carry (EDC)

But why use scrap materials to make one?

✅ Benefits of Using Scrap:

Cost-effective: No need to buy expensive steel or handle materials.
Environmentally friendly: Recycle and reduce waste.
Personal and artistic: Each knife tells a story. That old wrench could become your next favorite tool.

2. Types of Scrap You Can Use

Not all scrap is created equal. If you want a knife that holds an edge and doesn’t snap, you need good steel.

📌 Best Steel Sources from Scrap:

Scrap Material	Notes
Old saw blades	High carbon steel, ideal for knives.
Leaf springs (cars)	5160 spring steel—great toughness.
Wrenches or files	Often made from tool steel.
Industrial blades	Often contain hardened alloys.

🔥 Tip: To check if steel is high carbon, grind it and observe the sparks. More sparks = more carbon.

⚠️ Avoid:

Mild steel (used in fencing, nails)
Rusted-through materials
Stainless cookware (often too soft or hard to work with)

3. Tools You’ll Need

You don’t need a big forge or expensive grinder, especially if you’re a beginner. Here’s a basic list.

🔧 Essential Tools:

Angle grinder – For shaping and cutting.
Drill – For pivot holes.
Files – To fine-tune blade edges and parts.
Bench vise or clamps – To hold parts securely.
Hacksaw or bandsaw – For cutting metal or handle materials.
Sandpaper or belt sander – For smoothing.
Rivets, screws, or pivot pins – For the folding mechanism.

Optional (but helpful):

Belt grinder
Dremel tool
Forge (for heat treating)
Epoxy glue (for handle)

4. Designing Your Folding Knife

Before you cut or grind anything, you need a plan. Sketch the knife design on paper. Think about:

Blade shape (drop point, clip point, tanto)
Handle length and ergonomics
Type of folding mechanism (slip joint, liner lock, lock back)
Position of pivot and stop pin

You can also find free templates online or trace a folding knife you already own.

📏 Tip: Keep it simple for your first build. A slip-joint (non-locking) knife is easier to make than a locking one.

5. Making the Blade from Scrap

Let’s walk through how to turn that old saw blade into a shiny, functional knife.

🔪 Step 1: Cut Out the Blade

Place your blade design on the scrap metal.
Trace it with a marker or scribe.
Use an angle grinder or bandsaw to cut the rough shape.

🧤 Safety First: Wear gloves, safety goggles, and work in a ventilated area.

🔧 Step 2: Shape the Blade

Use a grinder or file to refine the edges and form the bevel (the angled cutting part).
Leave the edge a little thick if you're planning to heat treat it later.

🔥 Step 3: Heat Treating (Optional)

If you're using high-carbon steel, heat treating makes the blade hard enough to hold an edge.

Heat the blade until it's cherry red.
Quench in oil (vegetable oil works).
Clean it and bake in an oven at 400°F (204°C) for 1–2 hours to temper.

⚠️ Caution: Heat treating is advanced and risky if done wrong. Practice or get help from a blacksmith.

🪚 Step 4: Final Grinding and Sharpening

After heat treating, finish the bevel and sharpen the edge.
Use a whetstone or fine sandpaper to polish.

6. Making the Handle from Scrap

🌲 Handle Material Ideas:

Scrap Source	Material
Old wooden furniture	Hardwoods like oak, walnut
Plastic chopping boards	Makes a modern-looking handle
Micarta scraps	Strong and grippy
Bone or antler pieces	Natural and unique
G10/fiberglass scrap	Durable synthetic option

🪵 Step-by-Step:

Cut two identical handle scales.
Drill holes for the pivot, back pin, and any fasteners.
Shape and sand the handles to match your hand.
Finish with oil, stain, or sealant.

7. Assembling the Folding Mechanism

📌 Key Components:

Blade
Two handle scales
Pivot pin or bolt
Stop pin (optional)
Backspring (if using slip-joint)

🧩 Assembly Steps:

Line up the pivot holes.
Insert the pivot pin or screw.
Test the blade movement—should be snug, not too tight.
Add stop pin to prevent the blade from rotating too far.
Attach backspring if needed (for non-locking tension).
Use epoxy or pins to secure the handle scales.

8. Tips for Finishing

Once your folding knife is working, make it look and feel amazing.

✨ Finishing Touches:

Polish the blade with fine sandpaper or polishing compound.
Chamfer or round the handle edges for comfort.
Engrave initials or artwork using a Dremel or etching solution.
Sharpen the blade to a razor edge.
Test the opening and closing. Tighten or loosen as needed.

9. Common Mistakes (and How to Avoid Them)

Mistake	Solution
Using low-carbon steel	Test spark before starting.
Blade wobbles	Use tighter pivot pins or washers.
Blade won't lock/stay open	Adjust stop pin or backspring tension.
Handle feels rough	Sand down and finish properly.

10. Creative Ideas and Variations

Add a clip for your pocket.
Make a friction folder (no lock, held by tension).
Try a liner lock if you want to level up.
Use different materials like brass liners or colored G10.
Make a matching leather sheath (bonus project!).

11. Safety, Legal, and Usage Tips

Always use safety gear.
Know your local knife laws before carrying it.
Don’t sell knives unless you understand the regulations in your area.
Never use your folding knife as a pry bar or screwdriver.

12. Why This is More Than Just a Knife

When you make a knife from scrap, you're not just recycling metal. You’re:

Learning craftsmanship
Saving money
Building skills
Creating a unique, handmade tool
Connecting with history and tradition

Many famous bladesmiths started just like this—in a garage, with an old file and a dream.

Conclusion

Making a folding pocket knife from scrap is not only possible—it’s exciting, rewarding, and a great way to turn trash into treasure.

With patience, some basic tools, and a bit of creativity, you can build a tool that’s both useful and meaningful. Whether you’re a beginner or a budding bladesmith, every knife you make teaches you something new.

So next time you see a pile of scrap, ask yourself:

“Could this become my next knife?”

Chances are, the answer is yes.

Wednesday, August 6, 2025