Restoring a Free Rusty Knife With Cheap Home Products

Have you ever wanted to make a knife but couldn’t afford the equipment? I know I did, but my newly employed 15 year old self just can’t scrape up the money. My opportunity came about a month ago. I was fishing at a local boat ramp when a crazy bird lady showed up to try and attract birds. Desperate to not make eye contact, I stared at the ground and found rusty, abandoned knife. I stuck it in my bag and hightailed it outta there. Here’s how I, and you too, can restore old knives for cheap.

Rusty knife
Sandpaper
File
Buffing wheel and drill press
Carnauba wax
Metal buffing compound
Firewood
Chisel
Hand plane
Glue
Spray polyurethane

This is the most satisfying part. I used 80 grit sandpaper at first and just sanded until the rust disappeared. I then sanded with 80 grit sandpaper until most of the pits were gone. This takes ages, but stick with it. I guarantee it will work. Not all the pits can be removed, so I used 150, 220, 400, 600, and 1500 grit sandpaper to remove most of the rest of the black stuff.

I didn’t get pictures off the edge straightening, nor of the buffing process. What you need to do is use the file to shape the blade to how you desire. Mine dipped in a ton in the middle, so I rubbed it on the file to straighten it. I then evened out the thickness of the edge with the file. Next, add a metal buffing wheel to the drill press and buff with metal buffing compound. Mine wasn’t getting polished, but then I realized I was just using a random black chunk of something instead of buffing compound. 😬

A friend brought me a birthday gift 4 months late, and among the random knickknacks in it, there was a bundle of firewood. I decided to make scales out of a piece of firewood, so I grabbed a fun looking piece and split it using a chisel. Lo and behold, it was poplar. I split off a piece that was long and rectangular, and planed it to about the thickness I needed. I then cut off a piece about the size of the handle I wanted, and repeated the process. I then made sure they would fit before attaching them to the knife.

I used Gorilla brand wood glue, because it is what I had. It’s PVA formula turns out to work very well on metal. I’d say from my limited experience that the PVA is the way to go, but honestly, use whatever glue you have. I just rubbed the glue on the scales and clamped the knife in a drill press vise. I Iet it dry for 24 hours.

This is the worst part. It’s boring, and you feel like you aren’t making progress. For me, it was because my sandpaper got worn out so it took days to even out and shape. Simply sand it until you like it. Then, to prep for the next step, sand down to the finest grit you have, and then buff with carbauba wax.

At this point, your knife is ready for finishing. I had spray polyurethane, so I used that. Wrap your knife blade in tape. I did 4-5 coats. (I forgot) Between each coat, sand with your finest paper and buff it. After, let it dry for a few days. I then had to re-sand my blade a little, and re-buff it. I recommend wiping the blade with WD-40 if you have it. I didn’t. I also haven’t sharpened it yet because it’s going to be a gift and I need to buy disposable gloves so I don’t get the handle dirty.

You’re done! Use it for something, or put it on display. You should be proud. Use it well!