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I in this episode I will restore a Japanese kitchen knife with a lot of rust. Rust has eaten a lot of the steel away. Also the handle was not in good shape and the wood had split. I started by removing the handle. I used block of wood to hammer it off the knife.

I removed most of the rust with a laser rus remover that was loaned to me by W2M laser: https://w2m.fi/en/ Next I made jig to help me grind the bevel of the knife to my wanted angle. I needed to remove metal that was left porous by the rust to get a nice even edge. Otherwise the end result would be like a very unven sawtooth knife. After grinding the blade I sanded it all the way to 2000 grits and polished it.

For the new handle I used a piece of aluminum pipe which I bent into an oval shape and made a plug from birch to fill it. I cut the rough shape of the tang of the knife in it, but I left the hole a bit too tight on purpose. I did the final fitting by heating the tang with blowtorch and burning the hole to the correct size and shape. Next I took a piece of Finnish curly birch and drilled a hole for the tang. I glued the handle pieces together and sanded the wood down to teh shape of the aluminum pipe. The aluminum was then polished. The blade fit the handle firmly so I didn't add any glue. Finally I sharpened the knife with a sharpening stone.

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Some of my tools:
Threading tool set: https://amzn.to/3TsseDy
Polishing kit: https://amzn.to/3NuyeY8
Sharpening stone: https://amzn.to/3KwBZfL
Black gloves: https://amzn.to/2YY8a09

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