Some people order their raw materials from a factory, missing out on 99% of the fun… or suffering, we’re not sure which. To make that call, you need to look in on the process [IllyriaD] used to collect magnetite sand and turn it into a wicked-looking chef’s knife.
This began by collecting 150 pounds (!) of magnetic dirt from dry lake beds while hiking using a magnet pickup tool with release lever that he got from Harbor Freight. Several repeated magnetic refining passes separated the black ore from non-metallic sands ready for the furnace that he built. That is used to fire up the raw materials using 150 pounds of charcoal, changing the chemical composition by adding carbon and resulting in a gnarly lump of iron known as a bloom.
From there, it’s just a matter of beating the iron bloom into submission over at the anvil. [IllyriaD] details the process of flattening it out to a bar shape, then folding it over. Seven total folds are made for 128 layers, and in the gallery there’s a fantastic image that captures the striation when viewed on end. After being sharpened and polished, you can see where the bevel descends through those layers.
It’s delightful to see people working through the old ways and proving you don’t need a factory, as long as your true goal is to explore the process itself. Does this leave you wanting even more? [IllyriaD] left some insight about the process in the comments of the reddit thread. You probably also want to check out the tile-roofed hut built by [PrimitiveTechnology] without any modern tools.