Cardoso JD summer Build Off

[cardoso5fr]

I begin the project :)

http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06163.jpg
The material, a strong file, 7 mm thick.
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06164.jpg
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06165.jpg
My small salad fruit can forge and her new Burner :D
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06169.jpg
A piece of titanium i forged, and i hope to succeed to make bolster with it :D (that is a piece or air plane rolls royce motor.)
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06170.jpg
After some hammer work, (i'm a bad blacksmith and begin in that world :D)
i have a form and mainly decrease the thickness :D (and after the annealing)
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06171.jpg
I put the shape of the blade with the grinder and cleaned the tang.
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06172.jpg
It's stronger and longer than i used to make.
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06173.jpg
Some hole to decrease the weight. (the tang is always thick from 5 mm)
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06174.jpg
Grit 40
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06175.jpg
Grit 120
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06176.jpg
Grit 400
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06177.jpg
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06178.jpg
After 8 normalization and the oil hardening (differential hardening)
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06179.jpg
I forgot the filework (i did it before the hardening :D)
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06208.jpg
It's now in the kitchen oven at 240°C for 1h30 in order to make the tempering :D

Next step tomorow.

[RoadFish]

Looking great. Again, merci for your incredible step-by-step photos. That forge looks like a Mirage with the after burners lit! Has it ever taken off across the shop?

[cardoso5fr]

I have only build the burner two week ago and it's only the third time i play with :D. But i don't have make exploded the house and don't put in fire all the room. (i have to pay attention de be far enough of the forge with my clamp :D)

[cardoso5fr]

http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06209.jpg
After to have clean the blade just after the tempering.
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06210.jpg
Polishing the blade with an old belt 40 grit and some wd40.
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06212.jpg
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06213.jpg
After to have make a first etching with ferric chloride.
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06216.jpg
The piece of titanium. I flattened one side.
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06217.jpg
It's a pain to drill 8 mm of titanium.
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06218.jpg
First try
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06219.jpg
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06220.jpg
One bolster have his shape
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06221.jpg
I drilled the hole in the micarta plate
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06222.jpg
Cut and test
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06223.jpg
Other side
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06224.jpg
Vulcanic fiber and various piece :D
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06225.jpg
Handle shape
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06226.jpg
Everything is epoxied.I hope the micarta won't broked. i think i have tight too much the brass tube... (won't be a problem with the quantity of epoxy, but i would not be happy).

Now it's lunch time.

[cardoso5fr]

http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06229.jpg
After some grind.
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06230.jpg
The shape is cool
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06231.jpg
After grit 400
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06232.jpg
The first edge with an old belt grit 400
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06233.jpg
Convex sharpening, linoleum, grit 400 old belt and oil.
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06234.jpg
I etched my logo, i have to change my stencil that one seem to have some no desired hole...... I have 5 marks etched on the blade.... I consider that as my "logo":devilzeek. (if everything would have been great, that wouldn't have been a cardoso knife)
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06235.jpg
The mark.....

The sheath
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06237.jpg
A long plate of ABS.
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06238.jpg
First fold.
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06239.jpg
The belt loop.
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06240.jpg
Sheath is done

Data
File Forged.
4,8mm blade thick
12,5 cm sharp
Oil Differential Hardening . Tempering to 240-250°C during 1h30.
24,5 cm long
21 mm handle thick.
Titanium bolster (from piece or roll royce air plane motor) and red canvas micarta.
Two homemade mosaic pins (carboned steel tube, brass and stainless rod and tube.
Vulcanized fiber between the handle and the tang.

Weight 223g without sheath.
ABS righter sheath.
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06242.jpg
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06243.jpg
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06244.jpg
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06246.jpg
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06249.jpg
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/Image%20du%20Presse-papiers.jpg
As i thought, the micarta failed when i pinned the brass tube. But not a problem everything is glu and the failed is totaly filled with glu.
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06252.jpg
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06253.jpg
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06254.jpg
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06257.jpg
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06255.jpg
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06258.jpg
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06259.jpg
My logo with the undesired point :D
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06260.jpg
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06261.jpg
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06262.jpg
http://dremeltingpotes.free.fr/Photos/Fixes/Buildoff2009/DSC06263.jpg

[cardoso5fr]

Just for the fun
http://nl1.cetrine.net/tk1/photofunia/1237680000/21/43/359EA9EC-E816-4DA5-BA26-5E9ECC652FDD.jpg (http://galleries.cetrine.net)

[Desktop]

Beautiful work as always!
:devilzeek:devilzeek

[cardoso5fr]

thank you .
I'm happy you enjoy the journey in the workshop with me

[Centerfinger]

Nice job bro, thanks for the walkthrough. That micarta has a nice rich color.

[cardoso5fr]

Thank you Bro. I just seen i used exactly the same micarta last year :D. I think that is one special JD :D

[DCL]

nice knife and good step by step well top job as allways mate :)

DC

[jockotobling]

Thanks for taking me on the journey. That is a nice knife. It should serve well.

[cardoso5fr]

Thank you. I'm happy you enjoy the journey :D

[l2lku]

Congratulations on creating a gook looking knife.

[rinos]

Wonderful mess in workshop and beautiful result at end :matches:

[cardoso5fr]

Thank you both :D.
Mess???? What is Mess?
http://www.jerzeedevil.com/forums/showthread.php?t=46073
;)

[RoyalM]

Nice work there, sorry I haven't stopped by here sooner.

[2fulhundin]

Very nice, thanks for taking the extra time to show pictures, green inbound.

[cardoso5fr]

Thank you. That is not very longer to take picture when i work :D

[0311walkalot]

Great thread, love that knife! You're making a lot with a little, goes to show you don't need a fancy shop to turn out some great work.

[jimmyjo]

very cool and you always get my knife building juices flowing, it's just too bad my legs are attached to my lazy ass.

[ilovekittens]

Hey, at least the kitchen looks pretty clean. I like your style. Can you tell us a little bit more on how you made the forge and how well it works. Great looking knife. :madaddy: ILK

[cardoso5fr]

Thank you :)
The forge is really simple.

It's build on the model of the coffee can forge. I use a 10lbs salad fruit can. I drilled hole to receive the burner (on the next one i won't put the burner to the end of the forge but in the midel and i will try to have an angle of fire in order to obtain a vortex). Before to make my athmospherical burner, i used a simple butan torch.
The forge is full of ceramic whool and over the ceramic whool there is a refractory mortar (1200°c as for BBQ, but if you find mortar or ciment for ceramic oven it's really better. It will support 1400°c or 1670°c in function of the ciment.)
The feet of the forge are simply square of steel that i put in the whool and ciment.
The heat surface is 20 cm long for 6 cm hight and 6 cm width. That is enough to my work. (With the torch and the position at the end i was only able to forge small piece of steel. With the new burner as you can see the fire out the forge i can heat longer piece. That's why i will need to make a new and longer forge as soon as i will have found a gaz bottle empty or something like that :D)

The burner is simply three piece of plumbery steel. 3/4" each side. The injector is simple put in force in the top one that i drilled. The injector is a mild steel tube of 8mm i drilled with simply 1 hole of 1mm and obtured the other side with a screw that i put in force in the tube.
That is a friend ,Yann Colas, on a french forum whose explain me how to make :D. It's really efficient. I forge with butan now but the propan will give more power and will be economical.) And with the butan, after one hour of forge the fire began to be less powerfull. But it's probably because the heat surface is too small on my forge and there is possibly a lack of oxygène. But i'm far to be a specialist. That is totaly improvised work :D

[ilovekittens]

Thanks for the info! Sounds like a nifty little gadget. I assume the all the insulation prevents the fruit can from melting. Can we see a close-up pic of the inside? :madaddy: ILK

[cardoso5fr]

http://www.jerzeedevil.com/forums/showthread.php?t=36917&highlight=salad+fruit+forge

I believe to remember me that there are a picture in the topic when i start that forge. (but i'm at work and i'm not able to see the picture :D)

http://dremeltingpotes.free.fr/Photos/Fixes/JDBUILDOFF/JD37.jpg
On that picture there is some ceramic whool on the forge sole. But it's not a good idea, ceramic whool is really very toxic and the small particule very very thin and not good for the health. It's better to have a refractory brick or simply refractory ciment or mortar for the sole.
(i put away the ceramic whool since i have my new burner ;)).

[cardoso5fr]

The link for "how to make the burner".
http://www.couteliers.com/archives/bruleur/index.html
it's in french but the picture are easy to understood without the text.

The coffee can forge whick inspired mine
http://www.zoellerforge.com/coffee.html

And a version of two brick forge
http://www.britishblades.com/forums/showthread.php?t=10800

[ilovekittens]

Hey that's pretty neat. Thanks for the links. I may have to try putting something like that together in the garage if it ever warms up outside. Seems fairly inexpensive for someone who just wants to fiddle around. :cheesydevil: ILK