How to make a cast aluminum knife handle

"The Bladesmiths" • "The Bladesmiths" (2014)
Lost Styrofoam Casting, King of Random • How To Turn Styrofoam,...
Cast aluminum knife handle, knife making
Links to W2 steel for purchase:
Single bar -- www.ebay.com/i...
Three pack -- www.ebay.com/i...
Five pack -- www.ebay.com/i...
My steel on Amazon: www.amazon.com...
In these videos I forge Japanese blades by hand. I heat treat them, polish them, and make all the parts necessary for mounting them. These videos are targeted to people who are interested in metal art, blacksmithing, forging, knife-making, and sword-making or are simply interested in maker videos. I try to present content in a calm, relaxing fashion that anyone can enjoy watching, whether you participate in this hobby or not.
My most recent blades are made from modern high carbon steel, such as W1 drill rod and custom W2 steel bars. In the future I plan on smelting my own tamahagane and making swords and daggers from that ancient steel.
katana, wakizashi, tanto, habaki, fuchi, kashira, menuki, tsuba, tsuka, quench, temper, hamon, asmr, tamahagane, W2 steel

[@michaelripley9507]

Great idea. Thanks to you, I don't have to reinvent the "wheel."

[@kootenaiblades946]

You have an excellent channel, sir.

[@oldpuebloforge]

Thank you! Glad you like it!

[@pauloantunes8826]

Hey! you can also HT the blade first and then cast the handle. The molten aluminium will no damage the HT of the edge, but the ricasso will probable turn soft.

[@oldpuebloforge]

I think it will probably ruin the heat treatment of the part of the blade near the handle. The casting temperature of the aluminium is around 1,400 degrees F.

[@pauloantunes8826]

@@oldpuebloforge OFC but if you HT the blade with a torch the handle is never HTed anyway.

[@markgiles8527]

I like the Everitt Fight Knuckle Knife and have been wanting to make that but wasn't really sure how to cast the aluminium handle. This method has given me some ideas. The Everitt Handle has was too much details to use this method. Thanks for helping me move forward.

[@oldpuebloforge]

I'm very glad this video has been helpful to someone

[@elimerfeld1567]

Brilliant!

[@jackarrows1436]

THX 😉👍

[@oldpuebloforge]

You're welcome!

[@henrychiara4507]

Good video

[@oldpuebloforge]

Thanks, Henry! Those are your feet around 5:30, right?

[@henrychiara4521]

@@oldpuebloforge yeah

[@richardpreisler3352]

Super cool ! Just curious how sturdy the connection between the aluminium handle and the tang is compared to epoxi.
Also I think it will be 100% fine to heat treat before. just put the blade another 4mm in the sand and the blue colour wouldn´t even have reached the edge I think.

[@elusuarionoexiste7964]

Es hermoso 😀😎

[@oldpuebloforge]

Gracias!

[@raphlvlogs271]

less air pollutants would have been created if you used wax instead of styrofoam.

[@oldpuebloforge]

True, but the use of wax would require a completely different process. My goal was a process that anyone could do in his garage workshop. Wax would require equipment and processes most people can't afford and don't have time, money, or interest to learn.

[@darthdiabetes1250]

what should be the first thing I forge?. I was thinking is should make a Damascus billet first and then use that to forge my first project. I was thinking that would get me used
to the feeling of the hammer and technique but I'm open to any advice

[@oldpuebloforge]

For your first 10 projects, I would forge plain bars of steel. Forging your own Damascus billet and then forging something from that is not a beginner project. Also, Damascus tends to delaminate if you don't use correct technique. A lot of potential frustration there.

[@darthdiabetes1250]

@@oldpuebloforge thanks . I’ll probably make a fee leaves and then maybe a knife or something

[@davetimpson3645]

How do you know how much aluminum is needed for the handle? I've never done a casting knife handle but sounds very interesting?

[@oldpuebloforge]

I just guesstimated.

[@wis1024]

Would this method be possible with a pre heat treated blade? Or would the heat ruin the temper?

[@oldpuebloforge]

My feeling is that the heat of the molten aluminum would ruin the heat treat.

[@jisley7371]

​@@oldpuebloforge if you know the rate of approximate cooling, taking in to account the volume and shape of the handle, then you could probably get an idea as to the thermal impact to a heat treated knife. I'm thinking it may only reduce hardness at the hilt by a few points which isn't terrible. Have you repeated this project? Nice video, great to see.

[@raphlvlogs271]

is aluminium bronze mixture good for hilts?

[@oldpuebloforge]

I'm not sure. I don't know much about aluminum bronze or brass.

[@raphlvlogs271]

should aluminium be quenched?

[@oldpuebloforge]

No. There is no reason to quench aluminum.

[@guss4737]

do you polish blades for the public ?

[@oldpuebloforge]

I'm sorry, I only polish my own blades.

[@Christ_died_for_your_sins_777.]

Can i buy one?

[@oldpuebloforge]

I'm sorry, but I don't sell anything I make. I give them as gifts to friends and family.