For a long time the chief metal used for knives and swords was bronze, an alloy of copper and tin. Depending upon the percentage of alloying elements, bronze can be very hard and tough.
Pure copper, on the other hand, is soft and can only be hardened by work-hardening. So, the question arises: can you make a good knife from pure copper?
1. Make a mold
In order to cast metal, you need a mold. There are many different types of molds available, each optimized for specific casting metals and patterns.
You can make a mold using various materials, including metal, plaster, sand, and ceramic shell. Each of these methods has its own unique benefits, so it’s important to choose the right one for your project.
To start making your mold, you’ll need a frame made from wood or metal. The frame should be strong enough to support the weight of your object and the molten metal.
2. Heat the metal
Copper is an element that’s found in nature and can be used to make all sorts of useful things. The metal is ductile, malleable, and a good conductor of heat and electricity.
This makes it ideal for making a knife from. However, it can be tricky to sharpen a copper knife blade because the metal is so soft.
Fortunately, the guys over at Survival Skill Primitive have made a video on how to make a knife from copper.
They recommend using denatured alcohol or rubbing alcohol to wipe the metal down before you put it in the oven, so that any oils and fingerprints won’t be a problem.
Then, they advise annealing the metal a few times to ensure that it is completely solid before you try to chisel it into shape. This can be done in a garage or shop and is an easy way to ensure that your finished product is solidly crafted.
3. Chisel it
Before power tools were common, smiths used a variety of hand tools to cut and shape metal. One such tool was the cold chisel.
To make a knife from copper, you first have to chisel the metal into shape. This is a process called mokume billeting.
In the video above from the Survival Skills Primitive channel, you can watch two men make this very interesting blade. The process starts with a fire that they made by using mud and baking it.
Next, the men added solid copper pieces into the burning furnace to melt. The furnace had two chimneys through which stood an elongated plug, raised and lowered repeatedly to create a draft to increase the temperature of the fire.
4. Let it cool
In this video from Survival Skills Primitive, two men build a furnace to melt copper before pouring the molten metal into a mold to make a knife. This process is a sure fire way to produce a solid and very sharp metal blade that will last for ages.
The guys on the Survival Skills Primitive channel have produced several fascinating videos featuring their homemade tools and constructions. One of their most complicated projects is a copper melted blade.
To make a knife from copper, you’ll need a few simple supplies. A broken power hacksaw, about 2 feet of 3/4’’ type M soft copper tubing, a copper cap, some soldering flux and solder (either 50/50 or 60/40), and a little shop time. You’ll need to let the copper cool to anneal it to get it a shiny sheen.
5. Solder it
There are a few different ways to bond the metal together. Solder is one of the best options. This method will give you a strong bond that will hold the metal together for a long time.
To solder the metal, you will need a hot soldering iron and some good quality solder. Make sure that you choose a brand of solder that melts at a specific temperature and does not have any impurities.
Most flat metals like copper and tin can be soldered with a rosin-core type of solder. However, acid-core solder is also available for soldering harder metals.