The Eskimo: an Ulu With 3d Printed Handles! (Designed in Fusion 360)

This is an Instructable about how to make this knife with 3D printed handles. I have provided PDF files to print as a paper template to cut out the steel. Thank you for reading!

Update 6/30/24: DXF file added

Tools:

• Angle Grinder with Flap disk and cutting wheel
• Dremel or Worx Chopper with cutting disks and sanding disks (If you have a Worx Chopper, 3D print my Velcro sanding disks!)
• Drill capable of drilling through the metal you're going to use with a M4 or 5/32" bit (If you have a drill press, use that!)
• 3D Printer
• Xacto or hobby knife
• Hammer
• M4 Allen wrench
• Sharpie
• Personal Protective Equipment (PPE) (Safety Glasses, Ear Protection, Dust Mask)
• Vise
• Flat File

Materials:

• PDF Template (Below)
• 3d Printed Handles (Below)
• 2 M4x20 Socket Head Cap Screws
• 2 M4 Hex Nuts (
• 1/4"-1/8" Steel plate at least 12"x12"

Files

See files link for print instructions. You may want to start the print before you start the metal work, because the print took me 6 hours.

Start by using an angle grinder with a flap disk (or a Worx Chopper as mentioned) to remove the rust from your sheet of metal. Make sure that you clean an area big enough for the template! You do not need to get it super polished at this point, there will be a chance for further polishing later. Make sure that you wear proper PPE, especially if your metal is rusty.

Next, cut out your paper template using an Xacto knife(or hobby knife). Cut out the inside of the template first, if applicable. Do not do anything with the hole marks, yet.

Now, position the template over the polished area on your steel and trace all edges onto the metal using a Sharpie. Keeping the template in the same position, Cut a cross following the lines of the center marks of the holes. Then stick the Sharpie tip in the center of that cross to mark the metal. Remove the template, and slightly enlarge the hole marks that you just made for better visibility.

Next is drilling the handle mounting holes. Use a M4 or 5/32" bit. If you have a drill press, that would be preferable. Make sure that your holes are directly on your mark. If you have one, you might want to use a punch to mark a starting divot for the holes. After drilling them, line up a handle piece to make sure they fit. If you need to widen them, use a Dremel with a milling bit or drill a slightly bigger hole. Now, take your Dremel (or Worx Chopper. The point is that it's something small that can cut tight curves) and start cutting out the inner profiles of the design. Again, make sure that you are wearing proper PPE. While cutting, always err on the side that's not the design. It's always better to have to remove material than to have to start over! You may find it easier to make a scoring cut before you go all the way through. In one of the above pictures, you can see that there is a circled area. That is an example of what you don't want to do!

After cutting, use a hammer to tap out the design. You might need to cut further to completely release the design. Now bolt the handles onto the metal cutout (you will need to press the nuts into the appropriate handle piece), and trace the handle's outline onto the metal cutout. Then proceed remove the handles, clamp the design into a vise and grind the metal's handle part down to your markings that you just made. Repeatedly check for conformity of the 3D printed handle pieces' edges to the handle part of the metal. Also grind all other edges true except for the cutting edge. After grinding the edges(I used a Worx Chopper with a grinding blade), file the edges that come into contact with your hand smooth to remove any burrs from grinding. Now you can polish to your liking.

Now, use a grinder to put a rough edge on the blade. Then bolt the handles on. After the handles, hone the edge finer. Depending on the thickness of the steel you used, you may need to cut the bolts shorter so that they don't protrude past the face of the handle.

Wondering which way the handles go? See above picture.

Thank you for reading this Instructable! If you have any questions, comments, concerns, or design requests, I would be happy to respond!