From CNC Bevels to the Final Polish: Walter Sorrells on the Art of Blade Finishing

For those of us who spend hours in the forge or at the bench, we understand that the journey from raw billet to finished piece is defined by countless details. It’s not enough just to get the shape right; the edges must sing, and the geometry must be perfect.

In the latest look at the Nightfall Project, renowned knife maker Walter Sorrells guides us through a crucial phase: the transition from automated machining to the delicate, exacting art of hand finishing. This process, which many might overlook, is where the true skill of a seasoned knifemaker shines.

The Automated Start: CNC Beveling

Walter begins the day by continuing the CNC work on his new Nightfall design. The CNC machine handles the heavy lifting—establishing the basic bevels and creating the foundational geometry. While modern machinery is a marvel of precision, it’s only the starting point. The machine gives us the outline; the artisan must provide the soul.

He notes that mastering the approach to bevels requires years of iteration. Juggling the new Nightfall project with custom commissions keeps his bench busy, demonstrating that even with sophisticated equipment, the workflow is a complex dance between mass production and bespoke artistry.

The Critical Art of the Grind

The most fascinating section of the process, however, is the grinding work. After the CNC machine has done its job, the knifemaker must tackle the little tabs, the microscopic junctions where the bevel meets the tip. This step seems simple, but as Walter explains, it is incredibly exacting.

“If you get too slap happy you won't blend the tip and the rest of the bevel correctly and the knife could potentially at least end up in the scrap heap or you have to do a lot of adjustment.”

This isn't just about smoothing; it's about achieving a perfect blend that ensures the blade’s structure is sound and its lines are crisp. The grinding process is a systematic progression, moving through different grits to achieve depth and then refinement.

He moves from heavy grit belts to specialized finish work, utilizing belts like the 3M Triac Gator. This shift in tooling and grit is essential. The process involves progressively finer grits—moving from a relatively heavy grit to a 300 Micron belt, and finally to a 100 Micron belt in preparation for the heat treat. This gradual refinement is key to achieving a crisp, uniform grind line that promises optimal performance when the steel is finally quenched and tempered.

More Than Just Metal

It’s worth noting that Walter addresses the perception of modern knife making. Some might argue that working with a CNC machine isn't 'real' knife making, but he counters that the modern process, with its unique demands for material science and machine calibration, is profoundly challenging. He compares the physical skill of using a grinder to learning a practiced sport—it demands intense, continuous practice.

This entire process—from the initial CNC setup to the painstaking, careful blend of the tip—is a masterclass in controlled progression. It teaches us that in bladesmithing, every single step, no matter how small, dictates the final quality and function of the piece.

If the meticulous craftsmanship of a maker like Walter Sorrells has sparked your interest, remember that the Rogue Blades community is built for every facet of the blade hobby. Whether you're an experienced bladesmith chasing the perfect damascus pattern, a collector looking for the next piece for your display, or simply curious about the journey from billet to finished edge, there is a place for you. Don't just watch the videos—get involved. Find a certified Blade Angel near you, list a custom commission, or take a forge class to start your own journey.