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June 17, 2019
Restoring old broken pocket knife - New handle from bottle caps
Odd Tinkering
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I bought a lot of pocket knives for few euros. One of them was this rusty vintage knife. It was made in Solingen, Germany. I don't know anything else about it. It looks like it was made maybe in 50's and the handle could be made of ebonite. I wanted to try to do a recycled plastic handle because I thought it would look pretty similar to the original one although a wooden handle may have looked better. Also recycling is always a good thing these days. And I guess since I'm an "influencer", I should do something good with that every once in a while say maybe one or two of you get interested in recycling stuff because of this.
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I started by disassembling the knife. While doing this I noticed a previous owner had replaced one of the pins with thicker copper pin. And drilled also larger holes for the tools.Using one larger pin would have looked ugly so I decided to weld the holes shut and drill new holes.
Before welding I had to remove the rust. Also from inside the hole.That is important. I used MC-51 rust remover because that's what I happen to have. i'm not sure if there is huge difference to vinegar other than more pleasant smell. I might have to make a test video of different rust removers...
After I had welded the holes shut I was sure the original heat treating of the blade was gone so I had to do that again. In hindsight I probably could have done the quenching in oil. but seemed to work and the did not crack so it's all good. After hardening I tempered the blades in an oven. This makes the blades less brittle so they wont break.
The old brass sheets between the tools had also the large hole. So I needed to replace those too. I used a scroll saw to cut new ones out from sheep of brass. Then I stacked them in a pile and used double sided tape to hold them together while I used one of the old sheets as a jig to drill the holes for the pins.
For the handle as mentioned I used plastic bottle caps. i had sanded off the brand on the top because I didn't want to have any other colors in the plastic and also because that would probably prevent the caps from melting together. Ideally I would have an extrusion machine to make the plastic bar but I don't so I just made a mold from wood and used baking sheet to prevent the plastic from sticking to the wood. Without it you only have a sticky mess. I tried to press all the air out but I also had to do some fixing afterwards. It wound have been better to have a metal mold where I can heat up larger quantity on the plastic and the use vice to something to force all the air out. But next time I'll know better. This time I was really just counting that I can find a spot with no bubbles from inside that bar, and I did. The bottle capsare made from HDPE plastic. It
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