Best stock-removal tool for iron/steel?

[Russ Mitchell]

Hi folks.

I've got a fokos that's overbuilt and needs to be made thinner. Think basically a tomahawk head, only it was unfortunately built like one, rather than like something that goes on the end of a 3' haft to be wielded in one hand. I have an ancient and decrepit wheel grinder I inherited from my grandfather, but it's really not the tool for the job, as it cuts very crudely and only on a narrow surface.

Suggestions?

Thanks in advance.

[Tomburr]

A stationary belt sander with a coarse grit would work.

[AwP]

Bladesmiths love belt grinders. The longer the belt the better, though if you're not going to be using it tons then don't worry about getting an expensive 72" grinder.

[raito]

'Best', of course, depends on exactly what you're doing.

Cutting torch, for example, removes a LOT of stock very quickly. But I suspect it's not what you're after.

If you have an angle grinder, there's various cutting/grinding/sanding/polishing wheel available for that. And it's probably the least expensive alternative. And even if you only have a drill, you can cheaply obtain a mandrel to hold those attachments.

Then again, I've found a 14" bastard file to remove a lot, too. But it's slower going on hardened stuff.

[Gaston de Clermont]

I'd go with the angle grinder too. But take my advice on it with a grain of salt as I'm a little obsessed with them.

[Russ Mitchell]

Thanks for the advice, guys. I'm assuming for the angle-grinder I'd need some sort of industrial-scale vise to hold it still, right?

[hivemind]

Harbor Freight sells pretty big vices pretty cheap.

[Johann ColdIron]

Thanks for the advice, guys. I'm assuming for the angle-grinder I'd need some sort of industrial-scale vise to hold it still, right?

Becareful not to grind too quickly with an angle grinder. Their fast speed can have an impact on temper. That is why bladesmiths like belt sanders. I've used belt sanders on several axe heads that needed stock removal to eliminate a large chip in the edge.

Definetly use a vise with an angle grinder! Grinding freehand and catching an edge of the head could send it flying into something you care about. May want to consider mounting a temporary short handle that you can chuck in to the vise at different angles.

Still prefer a sander though.

[Russ Mitchell]

Gotta look at prices -- I have to admit, the finer control strikes me as a Good Thing(tm).

[Patrick]

If this is the only job you are going to do with the stock removal tool, get a good quality (Nicholson Black Diamond works fine for me) flat file in bastard cut. All of that is on the package, so just go with what I said. Get a decent handle for the file and get the largest file you can find at the hardware store. Probably 12".

The bastard cut is more aggressive than a fine cut, so will take more off. The longer file lets you get some oomph into it. The handle is so worth the $4 you pay for it when your hand isn't trying to grip that stupid tang (I started out trying to be cheap and that handle was worth the price after I realized why it was needed).

By the time you have paid for an angle grinder or a belt sander, gotten it home, set it up, figured out how to use it, and then remembered to go back to the store for eye protection, you could have been done with the job with a file.

If you honestly expect to use a power tool for more than one or two jobs, by all means look for a power tool. I made several knives with files as the stock removal tools before I sprang for anything more. I now have a Bader belt grinder, but most of what I do with it can be done with a file. It just takes longer. If this is the only job you intend to do, a file will go slowly, but it won't get ahead of where you can control it. That's important.

-Patrick

[Baron Alcyoneus]

If you have a spare hand, and air is available, you can use a blower while grinding and reduce the risk of burning the metal.

[Baron Alcyoneus]

Put down that bastard sword!