Finally got a start on it. Drew a rough outline and took it to my belt grinder with a 36 grit belt and a serrated contact wheel. It took me about 15 minutes to get it to a very rough shape. Considering that I could make a rough hollow ground blade from 440C or 154CM steel with this set up in about a half hour it’s not surprising that it took me such a short time and with wood as it’s like cutting through butter with a hot knife! Seeing that the kit I started with was quite small there was absolutely no need to use the band saw and I didn’t have much leeway as to the shape I wanted, but… whatever. Good practice for the next one.
Before:
After:
Setup:
I then set up the machine with an open platen and a 120 grit belt, but even that was too aggressive and I then decided to take out the Dremel tool with a carbide tip and some Micro-planers.
Setup:
Where I’m at now:
It’s still in a very rough form and not nearly to the shape I wish yet, but I’ll more likely than not continue with the belt grinder at times with 320 grit (with a VERY light touch) and some hand filling and sanding.
I’m in no rush and to be continued...