How to Design Your Own Pocket Knife

Written by eric cedric | 13/05/2017
How to Design Your Own Pocket Knife
Design your own custom Swiss Army knife. (NA/ Images)

Pocket knives have come a long way since the simple single-blade versions that fold into a housing. Today pocket knives are more like pocket tool boxes with a variety of blades and tools. As the pocket knife has evolved over the years, methods of designing and purchasing custom multi-tools or knives have advanced as well. The well-known Swiss Army knife company even has an online feature that allows you to design a knife to your specifications, or you can make your own from scratch.

Go to the Victorinox website. Click the "ToolMatch" link near the bottom of the page.

Select the tools and blades from the available list that you wish to add to your custom knife. Click the "Match My Tool" icon and choose the item you want from the list of available results. Double check to see that all the implements you've chosen are featured in the tool and click the "Add to Cart" icon.

Order the tool and provide payment.

Place the metal sheet blank into the bench vice and draw out the shape of your blade. Use the hacksaw or a metal jigsaw to cut out the blade out. File down the cuts with the metal file.

Wrap the end of the cut blade in tape and use the sharpening stone to grind out your desired blade shape. If you desire a serrated edge, use the file to grind down the indentations along the blade edge. Remove the tape.

Place one side of the handle into the bench vice so the inside is facing up. Close the vice onto the handle so that it has at least a 1/4-inch lip over the vice jaws.

Set the blade tang -- the bar that creates leverage when opening and closing the blade -- onto the handle. Place the blade next to the tang and place the second half of the handle onto the blade-tang combo. Open the vice jaws slightly to lower the full unit into the jaws. Close the jaws securing the knife into position.

Drill two small holes into the ends of the handle and screw the small setscrews into the knife. Remove the designed knife from the jaws.

Open and close the blade to loosen the tang. Add a small quantity of dry lubricant to the tang if needed to loosen the mechanism.

Things you need

  • Steel blade blank - 1/32 brass sheet
  • Bone handles
  • Two small metal screws
  • Power drill
  • Small screwdriver
  • Bench vice
  • Hacksaw
  • Dry lubricant
  • Metal file

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