Restoring old broken pocket knife - New handle from bottle caps

I bought a lot of pocket knives for few euros. One of them was this rusty vintage knife. It was made in Solingen, Germany. I don't know anything else about it. It looks like it was made maybe in 50's and the handle could be made of ebonite. I wanted to try to do a recycled plastic handle because I thought it would look pretty similar to the original one although a wooden handle may have looked better. Also recycling is always a good thing these days. And I guess since I'm an "influencer", I should do something good with that every once in a while say maybe one or two of you get interested in recycling stuff because of this.

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I started by disassembling the knife. While doing this I noticed a previous owner had replaced one of the pins with thicker copper pin. And drilled also larger holes for the tools.Using one larger pin would have looked ugly so I decided to weld the holes shut and drill new holes.

Before welding I had to remove the rust. Also from inside the hole.That is important. I used MC-51 rust remover because that's what I happen to have. i'm not sure if there is huge difference to vinegar other than more pleasant smell. I might have to make a test video of different rust removers...

After I had welded the holes shut I was sure the original heat treating of the blade was gone so I had to do that again. In hindsight I probably could have done the quenching in oil. but seemed to work and the did not crack so it's all good. After hardening I tempered the blades in an oven. This makes the blades less brittle so they wont break.

The old brass sheets between the tools had also the large hole. So I needed to replace those too. I used a scroll saw to cut new ones out from sheep of brass. Then I stacked them in a pile and used double sided tape to hold them together while I used one of the old sheets as a jig to drill the holes for the pins.

For the handle as mentioned I used plastic bottle caps. i had sanded off the brand on the top because I didn't want to have any other colors in the plastic and also because that would probably prevent the caps from melting together. Ideally I would have an extrusion machine to make the plastic bar but I don't so I just made a mold from wood and used baking sheet to prevent the plastic from sticking to the wood. Without it you only have a sticky mess. I tried to press all the air out but I also had to do some fixing afterwards. It wound have been better to have a metal mold where I can heat up larger quantity on the plastic and the use vice to something to force all the air out. But next time I'll know better. This time I was really just counting that I can find a spot with no bubbles from inside that bar, and I did. The bottle capsare made from HDPE plastic. It needed maybe 270 degrees celcius to start melting but the pieces stuck better together with a little more heat. Eventually I ended up using something like 350 degrees.

After making the bar I just cut and sanded it to shape and drilled the holes using the brass sheets I had made. As final step I tried if my metal polish compound would work on this too. It did a decent job, the best I could find when testing different methods, but you can't press the part against the wheel hard at all or it will start melting. So, patience young padawan.

Thanks for reading all the way trough. If you have questions, leave a comment. I might answer or not, I get a lot of comments and questions so I can't answer all but I try to read it all and answer a few every day.

Видео Restoring old broken pocket knife - New handle from bottle caps канала Odd Tinkering