Cleaver in the making!

[badbrass]

With the last purchase from Phil McCracken, in which I'm very impressed in the knife he sent me, as stated before! I asked him if he would consider to finish off a Cleaver I had cut out of AR-500 plate in which I had worked in a high-through put grain elevator! This Plate was used in the high-wear area's off the head of the transfer and shipping legs! But in time these needed to be replaced. Long story short! 15 years ago I cut a design of a cleaver out of this steel and it sat and did nothing! But now I have sent it to him, he has looked at it! made some adjustment's to the metal and it a go! We discussed the proposed shape of the cleaver itself & the handle, and the handle material, i think it will be great! Thanks!

[Phil McCracken]

^^^

Yes, this will be a great restoration project. I will post pics as I move on.

Thank you for the opportunity Badbrass...

[badbrass]

What I'v seen so far is Wow! took some metal off the handle, and slimmed it down a bit! Thanks for the photo's and discussion!

[CNP]

I remember you posting this picture some time ago. Excellent project.

[fordtruckin]

That’s pretty cool! How thick is the steel?

[Phil McCracken]

Originally Posted by fordtruckin

That’s pretty cool! How thick is the steel?

1/8"...

[Grizzly Adams1]

Originally Posted by Phil McCracken

1/8"...

Discarded saw blade from a mill would make nice source material, did a hatchet that way.

Grizz

[vanadium]

Good work in progress. I'll suggest you put wood on the handle

[badbrass]

Yes we did have a discussion on what to put on the handle! I think there is better material than wood today! I believe we are going to use acrylite for the handle material! But thanks for the suggestion.

Originally Posted by vanadium

Good work in progress. I'll suggest you put wood on the handle

[sns2]

What a really neat project!

I’m pretty confident that Phil will do a great job for you, as he did for me.

[Grizzly Adams1]

Originally Posted by badbrass

Yes we did have a discussion on what to put on the handle! I think there is better material than wood today! I believe we are going to use acrylite for the handle material! But thanks for the suggestion.

Something like that demands natural, preferably striking and attention getting. the artist in me.

Grizz

[badbrass]

Oh it's going to be "attention getting"

Originally Posted by Grizzly Adams1

Something like that demands natural, preferably striking and attention getting. the artist in me.

Grizz

[Phil McCracken]

Badbrass has been updated throughout the progress, along with pictures. Yesterday, he asked if I could share the work that has been done so far on this thread. No problems and here we go.

So the work scope was thoroughly discussed with him and all aspects were agreed upon.

I will begin with the handle shape. The profile was cut out:



The next step was to grind the entire cleaver edges, and do a little reshaping. For that, I used my 2x72 belt grinder with different grits. Then after that, it was finished by hand sanding.

The cutting edge was off "center" so I entirely flattened it out; and started it over. Bevels are now even.:





I then drilled the handle 1/4 inch holes. Normal bits did not work due to metal hardness, so I had to get a carbide twist bit. No issues.

After that, I worked on the flat sides of the blade. First, I used 2x72 conditioning belts (3 different grits). Once completed I hand sided both sides using 100/220/320 and 400 grits. Then to the bench grinder. I use 2 buffing wheels, using black and green compound. This process polishes the blade.

This cleaver had many deep "battle scars" from this piece of metal's previous life. I managed to get rid of most of them. These are a few left but I believe it will give this cleaver "character".

The cutting edge has now been sharpened.



So basically all there is left to do is make/install the handles, then a final blade hand polish. The handle material to be used was discussed with Badbrass, and a decision was made to use Inlace Acrylester. This is a polyester based material that exhibits a shimmering pearlescent quality when viewed in the light, and has amazing visual depth. I will not divulge the color he picked. All will find out when it is done.

So far, I have about 25 hours into it. it has been a challenging and fun restoration project, and I am thoroughly enjoying it...

[sns2]

Super cool. Enjoyed reading!

[badbrass]

Was sent a picture of a paper, he used to slice with the cleaver! I like what I see! Knowing it's sharp! Like I said it's going to be great! I started my work life as a papered cook , and was head cook, and department head at a hospital for 15 years!! But again that was 28 years ago!

[Bearski]

Very cool

[LeroyvdH]

Eet will cut

[Twisted Canuck]

Somehow, all I keep seeing in my head is this.....I loved the Swedish Chef!



Maybe Phil can dress up and do a short demo video when he is done? Bjork de Bjork?

[Phil McCracken]

^^^

Tack så mycket vriden canuck...hehe...

[7 REM MAG]

Just curious on the edge shape, my did you choose to go with a straight edge instead of a little bit of curve?

[badbrass]

I grew up using a flat edge blade. And that is what I asked for. I understand the curved blade aspect of it all? Very good question!

Originally Posted by 7 REM MAG

Just curious on the edge shape, my did you choose to go with a straight edge instead of a little bit of curve?

[badbrass]

All I can say is WOW! He just send me some pictures of the new handles put on the cleaver! Outstanding, and he said the pictures don’t do it justice! WOW!
I’m so happy I sent it to too him to complete this task. Wait for the pictures!

[Phil McCracken]

^^^

As per Badbrass' last message.

Cleaver turned out very nice. The lines you see at the bottom of the handle are not scratches, simply my lack of photography skills and poor lighting...

[pikergolf]

Very nice Phil.

[owlhoot]

I've been waiting to see this, Nice job. I like the handle.

[CNP]

Very nice!

[sns2]

good job

[WinFwt]

Very nice. Well done Phil.

[Bigwoodsman]

Beautiful job. What did you make that handle out of? Fantastic!

BW

[badbrass]

Originally Posted by Bigwoodsman

Beautiful job. What did you make that handle out of? Fantastic!

BW

It was made with Inlace Acrylester. He showed me a knife he made using the same material and I was Sold. Thanks.