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:

    I just started to list some of the stuff I use for my projects in this amazon storefront:
    It's affiliate marketing, so if you order something from here you'll help the channel for free! Thank you!

    Index of operation and materials:
    0:27 Remove handle with metal cutting band saw
    0:52 Remove rust with angle grinder and steel wire wheel disk
    1:25 Clamp with copper under holes to stop welds
    1:40 Stick weld the old pin holes to close them
    2:20 Grind excess weld with angle grinder and grinding disk
    3:00 Straighten tang with heat and vise
    3:26 Annealing
    3:38 Wire wheeling scale off
    3:48 Trace new blade geometry
    3:58 Cut most material with metal cutting band saw (steel soft after annealing)
    4:25 Refining shape and grinding new bevels on 2x72 belt grinder
    5:25 Wrapping with steel wire to help refractory cement sticking
    6:00 Refractory cement used to develop hamon (fail)
    6:20 Hardening
    6:30 Quench in warm vegetable oil
    7:00 Removing wire and cleaning blade
    7:29 Bad tempering. My oven is too small for this blade and home oven out of reach
    8:00 Final bevel grind
    8:15 Hand sanding to 400grit sandpaper
    8:37 Etching in ferric chloride for a dark matt finish (no hamon unfortunately)
    8:50 Making liners with red felt white paper and resin
    10:05 Iroko wood
    10:37 Glueing the handle stack with 5 min epoxy resin
    11:10 Grind square
    11:30 Drill tang hole, 10mm in diameter
    11:50 Mark and center puch guard holes
    12:00 Drilling with 2.5mm bit
    12:17 Grinding back side with dremel and thick cut off disk to save some file work
    12:36 Filing to size
    13:20 Tang dowel, cut to lenght on band saw
    13:30 Took to the exact diameter by spinning on a plate with hole drilled with same bit as the tang hole
    13:54 Splitting the dowel
    14:02 Enlarge the slot to match the tang thickness on slack of 2x72 belt grinder
    14:30 Final glue up with epoxy resin
    14:53 Grinding handle to shape on 2x72 belt grinder
    15:20 Hand sanding up to 600 grit
    15:48 Boiled linseed oil as finish
    16:08 Sharpening on the slack of the 2x72 with very high grit belt

    Thanks 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!



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  • Source: https://youtu.be/ebKqELkA2DI


  • arnhemseptember2009


     11 hours ago

    Great fun doing this with such a nice endresult!

  • Tizz


     12 hours ago

    16:41 whoa I didn’t know you liked Billie Eilish

  • Groot *_*

    Groot *_*

     20 hours ago

    All the tools he has and the blade still comes out dull

  • Wilhelm Taylor

    Wilhelm Taylor


    Do you even know what kind of steel it is? Ah, yes, the ultimate test: cutting a melon.

  • Zoes Dada

    Zoes Dada

     yesterday +1

    Where are you finding all these old, rusty, knives? Their probably evidence from a crime. I would have welded on more metal on the tang. Oh, I see now. You end up ruining it.

  • Eric 22898

    Eric 22898

     3 days ago +1

    Turning a 2 dollar knife into a high quality one with the help of machines that cost over 500 each

  • Moji Happyphone

    Moji Happyphone

     3 days ago


  • Beti


     3 days ago

    i enjoyed watching this video but PLEASE WEAR GLOVES

  • FADE


     3 days ago

    Pray for me that i dont lose them or my sister loses them lol🤣🤣

  • FADE


     3 days ago

    Im getting airpods tomorrow

  • Krunchy The Clown

    Krunchy The Clown

     4 days ago

    Not a very good knife if it can be cut by a belt of sand paper lol

  • Scoooda 115

    Scoooda 115

     4 days ago

    Me:trying to sleep

    Fly: 0:54

  • Luiz Ojeda

    Luiz Ojeda

     5 days ago

    11:21 am I love your videos you make old stuff into new looking stuff

  • Jayda Smith

    Jayda Smith

     5 days ago

    Yes music

  • Fatih KUŞ

    Fatih KUŞ

     5 days ago

    you made your handle thin 🤔

  • Hunter Coyhis

    Hunter Coyhis

     5 days ago

    Please get a guard for your grinder.

  • Some one

    Some one

     5 days ago

    I just watched a kitchen knife graduate from combat butcher knife school

  • Ahmad Ghanem

    Ahmad Ghanem

     5 days ago

    Great work

  • That MD Guy

    That MD Guy

     5 days ago

    My question is where do I get these antiques from in order to restore them I hope not finding them they could be old murder weapons from someone before we were born and now reimaged to be something completely different in its future 😳 I may be reaching but the thought did cross my mind 🤷🏾‍♂️

  • Wildan Izecson

    Wildan Izecson

     5 days ago

    also your material and the tools more than 2€ :v