Making a real Combat Knife as seen in the Fallout 76 videogame.
As soon as I have seen and used this knife in the game I knew I had to make a real one.
So I decided to challenge myself and make the handle out of cast aluminum. This required to model the entire knife (that was the first step, had to change the order to make a better video) in Fusion360.
Doing this I had all templates and patterns to make a proper two part mold out of petrobond sand. Of course the blade and guard needed to fit perfectly on the pattern to make it work so I really took my time to make them as close to reference as possible.
Overall a really nice and fun project!


Index of operation and materials:

0:24 Tracing the pattern on 3x40mm 1070 steel stock
0:38 Drilling tang holes
1:00 Slowly grinding the groove with the drillpress for repeatability
2:10 Cutting the blank with metal cutting band saw
2:35 Refining the shape with 2x72 belt grinder
3:18 Grinding bevels
4:05 Hand sanding to smooth out bevels and blade finish
4:28 Heating up to 800°C for hardening
4:37 Quenching in warm vegetable oil
4:51 Tempering for 2hr at 200°C
4:58 Cutting brass 5mm stock for guard
5:11 Drilling hole to fit tang
5:30 Filing to fit with needle files
5:48 Grinding to shape with 2x72
6:27 Design process in Fusion360
6:50 Printing in PETG with CR-10
7:00 Making the pattern with petrobond sand, dusting baby powder to help release parts
8:50 Inserting blade and guard
9:32 Making risers to improve static pressure (failed)
9:50 Melting aluminum, added degass agent and flux
10:51 Cutting risers, gates and flashing
11:11 Filing and grinding to shape
11:25 Spray to add contrast and show texure
11:49 Buffing pommel with cotton wheel and fine polishing compound
12:12 Grinding micro-bevel with high grit belt
12:34 Stropping on leather strip with fine polishing compound



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