Turn A 2€ Rusty Knife Into High-End Japanese Chef's Knife

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  • Published on:  Friday, June 21, 2019
  • I found this big knife at a local flea market in a bucket of "everything 2€" miscellaneous items. I bought it with the intent of lightly restoring it but after a close inspection I thought I was better off doing something more interesting with it since the construction was pretty bad, with un-even grinds, terrible pins and poor materials. After removing the rust I could also tell it has pretty much no historical value since it has no marking at all. So here we go! In this video I go through the entire process of turning it into a better looking (and better performing of course) chef's knife.The design is pretty close to a kiritsuke, but it's much bigger than most measuring 43cm (17inch) overall with 30cm (12inch) blade 6.5cm (2.6inch) wide and 2.5mm (0.1inch) thick.I tried to develop an hamon on the blade for aesthetic reason but without success, maybe the steel is not prone to show it since the harness is definitely different from spine to edge before and after tempering. Or maybe some other reason, I didn't wanted to spend the time to figure that out anyway. I had also another issue with the heat treatment where the refractory cement expanded and got stuck in the blade holder inside the oven, I had to quench everything... Yeah... That wasn't pretty at all! The handle is made of iroko and ebony wood, with a mild stainless steel guard and some red felt and white paper liners, the process of making the spacers is better described in this video:https://youtu.be/8tIaEAXYv-kIndex of operation and materials:0:27 Remove handle with metal cutting band saw0:52 Remove rust with angle grinder and steel wire wheel disk1:25 Clamp with copper under holes to stop welds1:40 Stick weld the old pin holes to close them2:20 Grind excess weld with angle grinder and grinding disk3:00 Straighten tang with heat and vise3:26 Annealing3:38 Wire wheeling scale off3:48 Trace new blade geometry3:58 Cut most material with metal cutting band saw (steel soft after annealing)4:25 Refining shape and grinding new bevels on 2x72 belt grinder5:25 Wrapping with steel wire to help refractory cement sticking6:00 Refractory cement used to develop hamon (fail)6:20 Hardening6:30 Quench in warm vegetable oil7:00 Removing wire and cleaning blade7:29 Bad tempering. My oven is too small for this blade and home oven out of reach8:00 Final bevel grind8:15 Hand sanding to 400grit sandpaper8:37 Etching in ferric chloride for a dark matt finish (no hamon unfortunately)8:50 Making liners with red felt white paper and resin10:05 Iroko wood10:37 Glueing the handle stack with 5 min epoxy resin11:10 Grind square11:30 Drill tang hole, 10mm in diameter11:50 Mark and center puch guard holes12:00 Drilling with 2.5mm bit12:17 Grinding back side with dremel and thick cut off disk to save some file work12:36 Filing to size13:20 Tang dowel, cut to lenght on band saw13:30 Took to the exact diameter by spinning on a plate with hole drilled with same bit as the tang hole13:54 Splitting the dowel 14:02 Enlarge the slot to match the tang thickness on slack of 2x72 belt grinder14:30 Final glue up with epoxy resin14:53 Grinding handle to shape on 2x72 belt grinder15:20 Hand sanding up to 600 grit15:48 Boiled linseed oil as finish16:08 Sharpening on the slack of the 2x72 with very high grit beltThanks a lot for watching, I hope you liked the video!Suggestions and comments are welcome.Leave a like and share to anyone who might be interested!★Patreon★https://www.patreon.com/blackbeardpro...★Website★http://blackbeardproject.com/★Follow me★Facebook ► https://www.facebook.com/BlackBeardPr...Twitter ► https://twitter.com/BlackBeardProjeInstagram ► https://www.instagram.com/black_beard...
  • Source: https://youtu.be/ebKqELkA2DI


  • Michael Sacy

    Michael Sacy

     1 months ago +1166

    Next : I wanna see you take a rusty Honda and turn it into a high end sports car.

  • Ro Bux

    Ro Bux

     2 days ago +37

    Today: 2$ rusty knife to high end Japanese knife
    Tommorow: 1$ pipe to high end Japanese sword

  • Devo Blanco

    Devo Blanco

     4 days ago +21

    how did you make it japanese

  • Papa Kilo Productions

    Papa Kilo Productions

     1 months ago +408

    How to turn a $2 knife into a more expensive looking $2 knife

  • Michael Neely

    Michael Neely

     2 days ago +6

    As much time and labor and tooling and equipment it would be cheaper to buy a new one.

  • Ibrahim Ali

    Ibrahim Ali


    Why did I think your channel logo was the Americas like in the map 🤦🏻‍♂️😂

  • Master Play

    Master Play

     2 days ago +2

    Человек у которого есть руки и они растут из того места

  • Omer Erdogan

    Omer Erdogan

     4 days ago +21

    Turn a 2€ rusty knife into high end japanese Knife with 1.000€ workmanship and using 100.000€ costed machinery.

  • gunsmith-45


     4 hours ago

    Never have I saw a more masterful work turn a 2.00 Dollar junk knife into a 1.50 junk knife bravo

  • Riften guard

    Riften guard

     4 days ago +37

    As a knife maker, i can tell, that wasn't a naturally rusty knife, i'm guessing you go with salt water by the pattern of rust 🤷

  • Trance Emerson

    Trance Emerson


    I prefer the electro-chemical rust removal technique.

  • Chris Tyler

    Chris Tyler


    No idea what happened there. How much to buy a new one?

  • blex



    i bet you do sous-vide cooking aswell lol

  • Pokey


     1 months ago +186

    People who understand what he was doing: oh
    Me: why is he smearing peanut butter on a knife

  • Simone Chiesa

    Simone Chiesa

     1 months ago +135

    This guy owns every kind of tools ever made by humans on earth but couldn’t find a chopping board!!
    Nice work though :)

  • Ana Pérez Calabuig

    Ana Pérez Calabuig


    Everything okay but please tell me that I'm not the only one suffering and worried because I think he is going to get cut or burned. Use some protection please

  • The hardy boys

    The hardy boys

     4 hours ago

    Some of those steps weren’t necessary but nonetheless an amazing restoration

  • Micke Bodén

    Micke Bodén

     1 months ago +215

    I love what you do, and I enjoy watching your videos. But this title is very misleading.
    In order to make it a real high end knife you need to know precisely what steel the blade is made of in order to have the right procedure for heat treatment.
    You can't just take any random sheap old knife, clean it up, arbitrarily hardening and quenching (and giving it a differential hardening) without some sort of hardness testing, i.e. a rockwell hardness tester at best or at least tester files.
    And then put on some bolster, liners, fancy woods handle and call it a high-end Japanese chef knife (not even calling it a Japanese-STYLE kitchen knife). 😅
    Don't get me wrong. I love the work you put into it! But it's important to be clear on what really goes into a knife in order to call it high-end, and even a Japanese chef knife for that matter.
    Please don't take offense!
    Anyways, love your videos. Keep it up!

  • Jonas Haus

    Jonas Haus

     1 months ago +233

    I must have missed the High-End and Japanese Chef part, but apart from that, nice job

  • Philip Ryan

    Philip Ryan


    Meanwhile us normies be shaving with a razor