How to Make an Alaskan Ulu Knife

We've been using an ulu knife in our house for many years. The knife and cutting board in this tutorial is based on one we purchased in Alaska. It's a quick and easy way to cut fruits and veggies as the curvature of the blade rocks back and forth on the mating cutting board for efficient slicing. Full list of supples and tools as well as a free PDF template on my website.

First thing I did was print the template and cut it out with an exact-o knife. I use that as a stencil and spray painted the outline on some sheet metal I got from the home center.

Using a metal cutting blade on my jigsaw I cut the shape out. I did use some tap magic cutting fluid to keep the metal well lubricated and was surprised on how easy it was to cut with a jigsaw. For the center I needed to drill out a hole for a place to insert the jigsaw blade.

I then finalized the shape on the disc and belt sander using 120 grit sandpaper.

The inside was shaped using a bastard file.

I sanded the face sides with my random orbit sander up to 240 grit and then stuck on some synthetic finishing pads to polish the metal.

Once sanded to 240 I then stuck on some synthetic sanding pads to polish the metal.

And then a bit of sandpaper to smooth out the rough edges.

For the bevel I just freehanded a reference line along the edge.

I started sanding the bevel using my belt sander to remove a bulk of the material.

Once I got pretty close I then used my Work Sharp 3000.

I did some final touches with a sharpening stone and making sure the the back was completely flat.

I trace out my shape, cut it out on the bandsaw.

And then resaw it in half for the two pieces that'll make up the handle.

I then glue everything together using some 5 minute epoxy.

Once the glue dries I then drill some holes for 1/4" brass dowels that is also glued in using epoxy.

And then some final sanding and a few coats of butcher block conditioner for a nice finish.

For the mating cutting board I'm gluing up some soft maple and walnut.

Once dry I plane it down to thickness and cut it into a perfect square before chucking it up on the lathe.

Here on the lathe I'm carving out a concave surface that should allow the knife to rock back and forth for efficient and fast cutting.

And once again I do some final sanding and finish it off with butcher block conditioner.

And that's it! You can find a list of supples plus a free PDF template on my website.