Mastering the Pattern: Building a Beginner's Knife for Cord Wrap

There’s a unique satisfaction in the simplicity of a well-executed project. For those new to the bench, or those simply looking to refresh their skills, starting with a piece designed for cord wrap is the perfect entry point into the world of knife making. It focuses the maker on the fundamentals—the geometry, the steel, and the fit—before tackling complex Damascus folds or intricate hamon work.

But a beautiful, functional knife isn't just about the handle; it starts with the pattern. As experienced bladesmiths know, the process of turning a concept into a usable billet requires careful planning. In this session, Walter Sorrells walks through the process of building a simple, yet robust, knife using Bohler M390 steel, focusing heavily on the pattern-making techniques that ensure the finished piece fits a sheath and looks clean, even when wrapped in paracord.

The Art of the Perfect Pattern

The most critical takeaway for any budding knife maker isn't the specific steel, but the methodology for creating the pattern itself. Walter demonstrates that there isn't one single way to go from idea to edge. Depending on your available gear, your intended production run, and your comfort level, multiple methods can be employed.

Choosing Your Tools for the Job

While the video showcases the use of a modern metal cutting saw, it also offers a powerful reminder that time-tested tools—like a granddad’s 75-year-old hacksaw—can perform just as well, provided the steel is handled correctly. When selecting steel, Walter notes that while M390 is used here, a beginner might find 440C a more forgiving steel for initial heat treating and general work.

The discussion on pattern making methods is a masterclass in efficiency. Here are the core approaches highlighted:

• The Scribing Method: For unique, one-off pieces, you can swab the steel with layout fluid and simply scribe the design directly onto the blank.
• The Template Method: For repeatable designs, creating a pattern out of Micarta or Delrin allows you to scribe the shape repeatedly, guaranteeing consistency across a batch of knives.
• The Existing Pattern Method: If you are starting with a piece you already own, simply laying it down and scribing around its profile is the easiest way to begin a new project.

Drilling the Holes: Best Practices

A major point of discussion is the sequence of operations. While it's tempting to drill the holes after the pattern is complete, Walter advises that for maximum flexibility and ease of adjustment, it is often best to drill the mounting holes while the steel is still in bar form, preferably clamped in a vise. If using a precise pattern, however, clamping the pattern to the steel and using the pattern's holes as a drill guide provides excellent dimensional control.

“There’s nothing wrong with taking any old knife, busting the scales off, and throwing some cord wrap around there. But that does mean that you end up with a handle that’s larger in this dimension.”

This build is a perfect example of modifying a design—adjusting the tang size and shape to ensure that even with the added dimension of the cord wrap, the finished piece maintains the original form factor and still fits the intended sheath.

From Bench to Blade Angel

Whether you are a seasoned knife collector reviewing a custom Damascus billet, or an apprentice figuring out the difference between a flat grind and a convex grind, the skills taught in this video are fundamental. The ability to plan, pattern, and execute a clean, functional piece is the heart of both the blade smithing and the knife making craft.

If you enjoyed seeing these techniques in action, don't let your skills gather dust. Finding a local community is the best way to level up. Find a Blade Angel near you, or take a structured forge class to deepen your understanding of billet steel and heat treatment. If you have a unique design or a piece you want commissioned, consider listing a custom commission. The Rogue Blades community is built for every creator, collector, and enthusiast.