Knife Swap Entry - Chip carving knife set.

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Project by ToddJB posted 11-10-2017 04:20 PM 4688 views 3 times favorited 25 comments Add to Favorites Watch

All, I submit to you my entry for our LumberJock Knife Swap

It’s a set of chip carving knives made for LJ doubleG469

When I decided that I wanted to do chip carvers I sent a personal message to LJ member Brit (Andy). He is an amazing carver and I knew he would steer me in the right direction. Andy recommended that I check out Wayne Barton and Marty Leenhouts. He said these guys were making the finest chip carving knives on the market. Wayne makes the traditional Swiss knives – just 2, the cutting knife and the stab knife. Marty added a third that he calls a “modified” knife, which is a bit steeper. I took a few queues from each of these guys and also did a bit of my own thing.

Okay – to the construction.

The steel is 1/16” O1 tool steel. The scales are Claro Walnut that I received years ago from a very talented hand saw maker named and fellow LJer, Erik Florip. Pins are brass. It’s all glued up with System Three 88 structural epoxy. The finish is Gloss Arm-R- Seal Gloss and Howards Feed-N- Wax.

These are my first knives (other than a marking knife I made for another swap). I watched a lot of Walter Sorrels YouTube videos on how to make knives. That guy is awesome and very informative.

I made a total of six knives, 2 of each. I kept the lesser. I started off by making paper templates that I glued to the steel.

Using an angle grinder and Dremel cut off wheel to cut out the rough blanks. Then used the bench grinder and belt sander to clean up.

Once they were close to the same shape I ganged them up and drilled the pin holes. At which point I could place the brass pins through all of them and filed them down together to their final shape.

From there I did the majority of the blades’ tapers – this was mostly down with files.
I used my coffee can forge to harden and the kitchen oven to anneal.

After the heat treating I needed to slightly reflatten them with sandpaper on a layout block.

I knew sharpening was going to be the biggest hurdle for me on this project and boy was it ever. I tried my makeshiftwannabe WorkSharp, I tried a modified Lansky system, I tried freehanding. I just couldn’t get it right. I got it close, but not good enough. In the end, Allen (LJ Bobasaurus) came to my rescue with his blacksmithing knife sharpening system on a bench grinder. It’s awesome, and now those puppies are sharp and should be easy to touch up in the future.

The Cutting and Modified knives have about a 10-degree bevel on each side for a 20-degree edge, and the Stab has a 30ish degree on each side for a 60-degree edge.

With the metalworking out of the way, wood was traced and cut out slightly oversized on the bandsaw. Then it was epoxied and pinned. Once that was cured I used files and rasps to shape. Sanded to 220, and started the finishing. There are about 5 coats of Arm-R- Seal. Last coat was wet buffed up to 3200 grit and then waxed with Feed-N- Wax.

Lastly, I made a little pouch. I know myself and the poor job I do of storing blades, and since these will likely not be used daily I wanted to protect their edges. The thick leather was left over Veg Tan from the leather mallets I made for a previous swap, and the main body is Suede. This was my first real venture into leathercraft too, so we both got a pouch out of it, as my first try had more than a few trial and error moments. Dying the veg tan and stamping the sir name were the hardest parts.

Anyway – That’s the project. I enjoyed it.

-- I came - I sawed - I over-built

25 comments so far

View Dave Polaschek's profile

Dave Polaschek

10544 posts in 2081 days

#1 posted 11-10-2017 04:33 PM

Great to see us all learning new tricks in these swaps. Looks like you turned out a very nice set of knives!

-- Dave - Santa Fe

View ShaneA's profile


7085 posts in 4098 days

#2 posted 11-10-2017 04:53 PM

Strong looking set there. Great work on em…

View doubleG469's profile


1033 posts in 1944 days

#3 posted 11-10-2017 04:54 PM

Todd did a great job on these and to see his build it shows through in the end. Thank you for a great set of carving knives. these will definitely be among my prized possessions.

-- I refuse to edit the photo orientation for this website any longer. It’s an issue they should address and correct. Gary, Texas

View crashman's profile


162 posts in 3845 days

#4 posted 11-10-2017 05:01 PM

All I can say is WOW!!!!! awesome job….....................

-- Jack R. Ellis

View jeffswildwood's profile


5160 posts in 3477 days

#5 posted 11-10-2017 05:06 PM

Very nice set Todd. You really put a massive amount of work into this! Thanks for taking part in the swap!

-- We all make mistakes, the trick is to fix it in a way that says "I meant to do that".

View 489tad's profile


4159 posts in 4511 days

#6 posted 11-10-2017 05:13 PM

Todd you did a great job with the knives. Doubleg must be smiling today. From the furnace to the leather pouch, well done!

-- Dan, Naperville IL, I.G.N.

View HokieKen's profile


22048 posts in 2638 days

#7 posted 11-10-2017 05:14 PM

Those are amaze-balls brother! I’m definitely gonna have to copy them bad boys! Love the handles and the leatherwork too. Excellent entry!

-- I collect hobbies. There is no sense in limiting yourself (Don W) - - - - - - - - Kenny in SW VA

View bobasaurus's profile


3749 posts in 4683 days

#8 posted 11-10-2017 05:28 PM

Todd, these are amazing. I’m glad I got to play with them in person. And you had to make 6 total knives including your set, that’s some serious work.

-- Allen, Colorado (Instagram @bobasaurus_woodworking)

View Mike54Ohio's profile


181 posts in 1978 days

#9 posted 11-10-2017 06:06 PM

Way excellent workmanship in all areas there. Be proud – nice work

-- It's only a dumb question if you ignore the correct answer

View woodcox's profile


2386 posts in 3511 days

#10 posted 11-10-2017 06:31 PM

Wow! Nice work. Times two. That claro looks so sweet.

-- "My god has more wood than your god" ... G. Carlin.

View Woodknack's profile


13594 posts in 3879 days

#11 posted 11-10-2017 06:35 PM

Handsome set of carvers!

-- Rick M,

View ToddJB's profile


8886 posts in 3630 days

#12 posted 11-10-2017 06:36 PM

Thanks, All! Tons of learning happened on this project. Now Gary and I have tons of learning to do with actual chip carving.

-- I came - I sawed - I over-built

View Brit's profile


8520 posts in 4342 days

#13 posted 11-10-2017 07:06 PM

Wow! You totally killed it Todd. Amazing workmanship my friend.

-- Andy - Old Chinese proverb says: "If you think something can't be done, don't interrupt man who is doing it."

View PPK's profile


1896 posts in 2309 days

#14 posted 11-10-2017 07:27 PM

Great set! Really well executed.

-- Pete

View ToddJB's profile


8886 posts in 3630 days

#15 posted 11-10-2017 08:09 PM

Thanks, guys. You should definitely go check out what I received in return – cause it’s amazing.

Click for details

-- I came - I sawed - I over-built

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