i have little to no experience in metal work but does anyone know how to make a knuckle duster with a knife attached on the end?

what would be the easiest method of making this?

should i heat a large piece of metal and bend it to to make a knuckle duster and solder a blade onto the side?

would their be an easier way?

examples:

http://www.mondotees.com/ProductImages/bangonicons/knuckleknife.jpg

http://lh5.ggpht.com/_FTUe55LhnYQ/SE0qIeGmNfI/AAAAAAAAAHo/bPw0v1mcMTc/knuckle+duster+knife.JPG

Thats a knife with a knuckle duster attached not a knuckle duster with a knife.

Plus, i don't think you have the nessecary skills orequipment to make that, why dont you buy one?

Sorry i can't be of more help.

Thats a knife with a knuckle duster attached not a knuckle duster with a knife.

Plus, i don't think you have the nessecary skills orequipment to make that, why dont you buy one?

Sorry i can't be of more help.

im aussie...customs wont allow such an item

what i recommend is make a bunch of rings first then make a knife from a bladestock. solder the rings on the tang when youve done that. no need to weld.

i would also suggest you draw out a scale drawing of what youre making. it makes it much easier

ive made a few knives a while ago, and ill post pictures tomorrow (its 3:30 am here)

im aussie...customs wont allow such an item

Sorry, i forgot your country was such a cunt for customs.

Automotive leaf springs. If you have a drill, a bench grinder, and an angle grinder w/ cutoff wheel it wouldnt be too hard to drill out the knuckles and shape the blade with a grinder.

I have a very large knife like this, fun stuff.

Automotive leaf springs. If you have a drill, a bench grinder, and an angle grinder w/ cutoff wheel it wouldnt be too hard to drill out the knuckles and shape the blade with a grinder.



This, but I would'nt use the leaf springs because they are already hardened and it would be a real bitch drilling and grinding through hardened steel. Or if the duster dos'nt have to be steel, you can take a knife blade with a tang and melt a handle mold with plastic, aluminum, fiberglass resin, ect.

to make blades, generally i use these steps:

1)cut a strip of metal about the length you want.
2)draw the outline of the shape you want
3)use a grinder (angle, or bench) to do rough shaping.http://i132.photobucket.com/albums/q30/fartx2/SDC10087.jpg
4) use a marker and simple right angled triangle trigonometry to find where you need to start grinding an edge. draw it on the metalhttp://i132.photobucket.com/albums/q30/fartx2/SDC10071.jpg
5)grind the tip to a point before anything else.
6)grind the rest of your bladehttp://i132.photobucket.com/albums/q30/fartx2/SDC10088.jpg
7) heat treatment.

edit: forgot to mention, if youre like me and dont have a bench grinder, i would suggest using a coarse file (but obviously not a rasp) rather than an angle grinder for making edges. its slower and you have few chances of making a mistake. you COULD make the whole thing with a file, but it would take a while.

^ What metal do you use? Just mild steel or stainless?

Make a blade from stainless teel.
Make a mould for the knuckle duster bit from plaster.
Stick the blade handle/tang into the mould, and pour brass into it.
Cool, then heat-treat the blade and sharpen it.

Thats basically all you have to do :)

Now google it and start working.

its galvanised mild steel from a hardware store.

stainless steel doesnt make very good blades, as it doesnt hold and edge too well, though it can be good if you are going to go into lots of rough conditions.

though the reason i chose mild steel is because its a lot cheaper and its more easier to find the stuff you want

^ What metal do you use? Just mild steel or stainless?

Make a blade from stainless teel.
Make a mould for the knuckle duster bit from plaster.
Stick the blade handle/tang into the mould, and pour brass into it.
Cool, then heat-treat the blade and sharpen it.

Thats basically all you have to do :)

Now google it and start working.

i actually like this idea as it seems very easy. but a few questions...

how would i mould the duster? i can picture plaster being shaped into the knuckle duster but cant understand how i would make finger holes...

also where would i get brass and how hot would i need to heat it in order for it to liquefy?

also thanks mantikore for blade tutorial, i sent it to my friend and he is having a go and will hopefully show me his homemade knife tomorrow...thanks

Just buy a knife, then cut pieces of pipe for the rings and weld them to the knife. If you need to modify the rings to make it more comfortable you can just use a saw to cut the pieces and move things around a bit.

You can use anything you want. Get some old candles and melt into a sqare roughly the same length and width and thickness you want the duster to be, then carve it into shape. The holes can be smoothed with a lighter and a small knife. Basically you want it as perfect as possible, as it saves work.

http://en.wikipedia.org/wiki/Casting#Investment_casting

Basically, the wax is placed into a mould, which plaster is then poured into. The key is to have no air bubbles in the plaster. Im not sure how it would work with large quantities, but ive done it before using a small ring i made from brass, although it was made in a centrifuge into which molten brass was poured and basically injected into the mould. The wax is then melted out, which leaves a cavity behind(for the metal). Excess wax should just burn off when the brass is poured in.

Get the blade and drill a few holes into where the tang will be. Try and incorporate the blade into the actually handle before it's casted, so the brass will hold it in place. The holes will allow the brass to flow between and grip it permanently. Dont temper the blade before doing this, as the heat from the brass will cause it to untemper itself.

Brass melts at different temps, but an 85-15 will melt at 900-1000C or 1650-1750F. Brass can be easily gotten from hold taps and some door handles.

Do your research. Find a few designs you like, then draw them out with a blade. Made sure it has ~5mm extra room in the finger so it doesnt get stuck(incase you needa ditch em fast).

Get a piece of cardboard and cut it to the shape you want your knuckle duster. It doesn't have to be perfect you just want to get the sizing right.

Get a piece of half inch thick or so steel (preferably tool steel) and cut it to the size and shape of the cardboard. (you'll want to smooth the edges)

Buy the kind of knife you want on your final product and take the handle off.

Cut a slit in the top of the knuckle duster to accommodate the tang of the blade.

Put the tang in the knuckle duster and drill two holes through both, then rivet the blade in place.


Disclaimer: this process involves dangerous tools and the resulting product is also dangerous and may be illegal in your area, blah blah.

If you are using mild steel then I recommend you use a drill press to create the holes in the duster. Then file the edges of the holes round. That seems like the easiest way to me. Casting is difficult and takes a lot of time.

This, but I would'nt use the leaf springs because they are already hardened and it would be a real bitch drilling and grinding through hardened steel. Or if the duster dos'nt have to be steel, you can take a knife blade with a tang and melt a handle mold with plastic, aluminum, fiberglass resin, ect.

Uh, no, leaf spring steel is not hardened steel. Think about it. If it were hardened it wouldnt make a very good spring would it? You use spring steel because you can heat treat it to be hard, but not too hard.

If you're really into casting things in brass/bronze dont do it in plaster, most plasters will crack at the heats needed for brass work. Use oil sand, or 'green sand', to make a lost-wax investment casting.

It's a helluva lot simpler to cut out a knife from a piece of steel with the shape you want than it is to use an existing knife and get involved in metalcasting.

btw, the plaster was baked in a kiln @ 800C for 4-5 hours to make sure it was dry(so it didnt crack).