How to Make Plastic Knives
- 1). Draw the shape of the plastic knife blade and handle on a piece of paper. Draw the handle so it is no more than four inches long. A simple blade design is the shape of a household paring knife. Cut out the shape.
- 2). Trace around the plastic knife cut-out on a piece of 1/8-inch thick plastic with an oil pencil.
- 3). Use a scroll saw to cut out the plastic knife shape from the 1/8-inch plastic.
- 4). Secure the blade of the knife on a horizontal plane between the bench vise rubber blocks. Use a flat file to shape the edges of the handle. Reposition the knife as needed for shaping.
- 5). Reposition the knife in the bench vise, securing the handle on a horizontal plane between the vise rubber blocks so the top of the blade is facing up. Shape the top of the blade with a flat file.
- 6). Reposition the knife in the vise so the blade is facing up. Use a flat file to bevel the edge of the blade.
Complete the bevel with the outward motion of the flat file. Do not try to bevel the edge pulling down over the blade. The plastic will crack. Use a 60 to 70 degree bevel. This is the easiest bevel to sharpen on a whetstone after the knife is completed. - 7). Use a whetstone and oil lubricant to sharpen the edge of the blade.
- 8). Use liquid sandpaper to remove all scratches from the blade and handle. Continue wiping the beveled edge of the blade with liquid sandpaper to sharpen. Wash the blade with soap and water when finished.
- 9). Optional: Wrap electrical tape around the handle to the desired thickness.
