Stuart Mitchell Custom Knife Process

[shotguntom]

Probably like many on here, I find myself getting increasingly envious of the to be owners of the knives being posted by @Stuart Mitchell . Well, I hit breaking point and reached out to design and have made my own custom knife.

I thought others may be interested in the process and perhaps Stuart can add some further details of the work performed at each stage.

To start with, there were discussions on what I wanted and some general design ideas. I based the blade profile of the knife on his P90 range but with a bespoke designed handle. Following some ideas being shared, Stuart proposed the following and I agreed.



This was then cut out in his SF100 steel made in Sheffield.

 

[shotguntom]

Once cut out, off it goes for heat treatment. Which changes the microstructure of the steel, so it develops the required properties of hardness, toughness and corrosion resistance. The process includes heating it to temperatures in excess of 1,000 degrees celsius.

 

[Dazb1967]

Looking forward to seeing it finished and I know you’ll be happy with it

 

[Stuart Mitchell]

Evening, Tom, thank you for this. Let's see how it goes

I posted something on my socials quite recently about this subject, about communication with clients throughout the design and ensuing making stages of their knife. That post might be on here somewhere, too; I can't recall.

But the below is it, copied from my Facebook.

I am currently working on a pair of deer stalking knives for a client, and a fair wind this morning will hopefully see the duo finished and ready for sheathing.

Below is a small selection of some of the 'update' photos that I have shared with my customer as things have progressed. WhatsApp has revolutionised communication with my customers.

Long gone are the days when I had to take photos on an actual camera, take that home, download to a computer and email them off; that was a PITA.

Today, we can stay in touch in what is almost real time, with photos or video. Not only does that mean I can update them, but I can also run ideas past them. If a modification comes to mind that I think will improve the overall job, I can explain and ask the question, there and then.

Apart from standing beside me in the workshop (which I have also done), this makes the commissioner truly part of the process of bringing their commissions to life.

I am not for one moment suggesting that I am the only maker who does this; I am fairly sure that I am not. It has revolutionised the whole process though. For the better.

 

[shotguntom]

Once back from heat treatment, Stuart grinds a hollow in the tang which makes it easier to flat the taper. Which in layman’s terms means you get a flatter outer surface making it easier to get a better fit when the liner and scales are added. I believe it also helps with adhesive performance and the balance of the knife too.

 

[WalkedUp]

Very interesting keep us posted

 

[shotguntom]

Next, the blade profile of the knife is ground

 

[shotguntom]

The blade then gets polished, as well as the makers engraving, unique number and steel info.

 

[Stuart Mitchell]

I’m at work just now @shotguntom but when I get home I’ll add a bit of info in here, if that’s ok?

 

[Stuart Mitchell]

I thought I'd add a little more detail about the tang tapering, it might help someone along.

On a belt grinder, this one in fact...





... the RHS of that, but running a contact wheel and a 36g abrasive belt, I'll grind that initial concave channel out the middle of the tang, this is the start of my taper, this channel goes from zero by the front bolt hole to a thickness of a little over my desired and intended thickness of the tang at the butt.

Then I switch to here...





... that is where I begin flatting the sides of the tang, running the same 36g abrasive along the raised platen that you can see fixed to the wider bed.

I do it that way as grinder one is much more aggressive, less steel in contact with the abrasive, I assume? So it is a little easier and a little quicker. So once my grinder 1 concave channel is in place, all grinder 2 is doing is grinding around the edges of the tang, not the whole surface.

@shotguntom 's photo shows it quite well. You can still see the remnants of grinder 1's channel, but grinder 2 has flatted all around the tang edges. Perfectly flat, perfectly tapered.

 

[shotguntom]

Next comes possibly the hardest decision of a custom knife - what scales (handle) and liner?

I knew I wanted a dark coloured natural scales with a bright liner to compliment it.

I initially looked at using buffalo horn but after seeing this knife - PORTLAND SERIES 2024 — Custom Knives - Stuart Mitchell Knives I decided to go for something similar and settled on African Blackwood scales and a red liner. Africa has a special place in my heart and love the dark coloured wood.

With a combination of adhesive and bolts, Stuart got to work

 

[shotguntom]

Once the glue has dried, the handle is then shaped all by hand!





The African black wood gives a lovely rich colour and subtle beauty.

 

[Stuart Mitchell]

Big day tomorrow @shotguntom, expect new photos

 

[shotguntom]

Now back from the leather worker, who I asked to ensure the sheath had a top snap to reduce the chance of me losing it.

Stuart then ground the bevel.

Here it is all finished up:

 

[Bavarianbrit]

Evening, Tom, thank you for this. Let's see how it goes

I posted something on my socials quite recently about this subject, about communication with clients throughout the design and ensuing making stages of their knife. That post might be on here somewhere, too; I can't recall.

But the below is it, copied from my Facebook.

I am currently working on a pair of deer stalking knives for a client, and a fair wind this morning will hopefully see the duo finished and ready for sheathing.

Below is a small selection of some of the 'update' photos that I have shared with my customer as things have progressed. WhatsApp has revolutionised communication with my customers.

Long gone are the days when I had to take photos on an actual camera, take that home, download to a computer and email them off; that was a PITA.

Today, we can stay in touch in what is almost real time, with photos or video. Not only does that mean I can update them, but I can also run ideas past them. If a modification comes to mind that I think will improve the overall job, I can explain and ask the question, there and then.

Apart from standing beside me in the workshop (which I have also done), this makes the commissioner truly part of the process of bringing their commissions to life.

I am not for one moment suggesting that I am the only maker who does this; I am fairly sure that I am not. It has revolutionised the whole process though. For the better.

A blast from your past?

 

[Stuart Mitchell]

A blast from your past?

Not many