Now onto the handle design. Since this is a 1/4in thick steel, this is still too heavy, so to lessen the weight I’ll be removing a good majority of material from the handle.
To do this I drilled holes in the four corners of the section I’m removing and then used a cut-off wheel on the angle grinder to connect to the dots length-wise. From there I used a small file to connect the dots width wise. Just after breaking the section out, it looks like this.
I went to work with the files to square everything and give it a cleaner look.
This is what it looks like all squared up.
In the next part, I’ll detail the heat treatment procedure and complete the finish sanding and sharpening.