Repair a Rusty Japanese Knife over a month

At first, I thought it would take me only 2 or 3 days to finish sharpening it, but I ended up spending a

month

struggling with this

knife

. First, remove the handle of the

knife

. I decided to cut the handle lengthwise with a hacksaw since it was possibly attached with metal nails. When I made a cut with a hacksaw, it looks like no nails were used. But I can't remove the handle... I finally broke it with a hammer. It would have been better to have done it from the beginning. There is also a part that is badly dented from rust and looks like the metal has been eroded.

Use a sandblaster to scrape off the rust and check your progress. It feels good to sandblast rust off. All rust has been removed. It's hard to see in the video, but the rust is deep. Grind with a #80 whetstone block until the surface is smooth. It is easy to use an electric grinder, but it can be tempered with heat. Since the grinding amount is large, there is concern that the shape of the cutting tool may change. Since it is sanded by hand, it naturally takes time and effort. All dents could be removed. A #800 diamond resin sharpening stone is used for rough cuts to correct chipping on the cutting edge.

The whetstone is lightly applied to see the shape of the blade.刃の形が悪いことが判明。 And I started to realize that I couldn't handle it with the #800 whetstone. I don't have a sharpening stone thicker than #800. I'm trying to make something. I tried my best with a #800 whetstone, but still couldn't fix it. You can see a large, deep rust erosion at the bottom left of the screen. I bought a #160 whetstone because I couldn't finish the job with #800. I sharpened it quite a bit, but the edge is still

rusty

. The

rusty

holes are still deep. Just sharpen afterwards... The rust spots are getting smaller and smaller.

Wheel surface adjustment Adjusts the shape of the tip. It took quite a while to form the tip. Rust and nicks were cleaned. Next, sharpen the flat part of the knife. Doodle with a pen and see what happens. High places where the scraped part is high. Grind it until it is flat. The base is still dented. A bit later! almost flattened. Cut out the curved part with a router. Work carefully to avoid overheating. I was able to polish it beautifully. Polish with waterproof paper #600 → #1000 → #1500 to remove scratches. The big scar has disappeared. Polish the back in the same way.

Sharpen the back of the knife. I finished sharpening with #1500. It has a faint shine. Finish by polishing with compound. It has a mirror finish. Make a knife ring from brass. Cut out with a jigsaw. Adjust the inner diameter with a metal file. Rough cut with an iron saw. Finish the outside diameter with a disc sander. It gets hot from friction, so I worked while cooling it with water. The knife ring is complete. process wood. I adjusted it to fit perfectly on the rim of the knife. Make sure the knife ring fits. Glue the knife ring with epoxy glue.

Protect with a mask. Cut off unnecessary parts. Cover the sides with mask. processed by a router. Write a marking line for the knife handle to fit into. Drill a pilot hole. Adjust the shape with a chisel. Shape the handle with a planer. Work carefully. It's long if you turn it into an uncut video, but the job was completed in about 15 minutes. Finish with sandpaper. Grease the handle. Insert the handle into the knife. Tap the end of the handle firmly to insert it firmly. Fill the gap with epoxy glue. Finish by sharpening the blade. Finalized. Finally finished with compound. before after I am satisfied with the finish.

The newspaper can be cut slightly.