Hi guys, today I took advantage of a half day off and, with the excuse of the next seminar, I built by myself an aluminium training knife. If you have a minimum of familiarity with drill and flexible you’ll make it in a couple of hours.
An aluminum rod.
About a meter of 3mm diameter cord.
Flexible (angle grinder) with cutting disc (thin) and abrasive disc.
Drill with 5/6mm metal drill bit.
One pair of files for metal, medium and fine.
I chose aluminium because it is a light metal, it’s easy to work with and does not rust. To get a bar of the right size just look in the curtains department of a DIY shop; it’s a 40 x 3 x 600 mm bar used to keep your indoor curtains tight; it costs about 6$ and with it you can build at least a couple of knives. Let’s start with the design that, more or less, will look like this:
Transfer the drawing onto the aluminium bar with an
indelible marker, then start cutting it with the hose, taking care of the
curved parts. After cutting it, use the abrasive blade and round it ALL, taking
care not to leave any edge that may cut you or your training partner. Go over
everything with the medium file, then with the fine file and finally with
sandpaper; at the end the piece must be completely smooth and rounded (above
all, no tip!).
Now create the two holes with the drill; use a small drill
bit (2mm) and then enlarge the hole with a 5/6mm drill bit. Remember to remove
The final step is to cover the handle of the knife with the
cord: bend it in half and pass it through the upper hole, then continue along
the handle crossing the two ends until you reach the second hole at the base of
the handle. Pass the two free ends of the cord through the second hole, tie a
knot and you will have finished your training knife!