Insanely Big Butcher Cleaver Restoration. SORT OF...

Yes, I did it again... My own style of restoration for this incredibly cool butcher cleaver!
I found this beauty in a near by flea market, as always, and luckily I got it for super cheap as the seller was very happy to let it go being so heavy and inconvenient to carry around at flea markets.
Needless to say this project is pretty unconventional, but I guess most of you know I have a thing for odd looking cast handles by now!
Anyway, it's always challenging to pull off a cast handle with lost foam and these scales were no exception at all! It's also the reason why I haven't posted on my regular day last week, making all over before casting takes a real long time. As you can see from the video the cast failed three times, one of these the tang shifted up and out of the foam pattern due to the weight of the blade, the other two fails were similar with uncomplete cast, one time just after the sprue and the other in the middle of the handle. The fourth time i decided to add another foam channel to the handle to act as a vent (but I also filled it with molten aluminum just in case) and it worked out very well.
I had a chance to remove a partially formed cast handle at 6:40 after one of the fails and I can assure it holds incredibly well. I think there is no way (other than a metal cutting band saw) to get the final scales off the handle.
This is a showpiece. This project is just for fun, I am aware it's not a practical approach to handle making. I just want to entratain and hopefully inspire others to get hands dirty and make something even just for the fun of it!
I just started to list some of the stuff I use for my projects in this amazon storefront:
www.amazon.com/shop/blackbear...
It's affiliate marketing, so if you order something from here you'll help the channel for free! Thank you!
Index of operation and materials:
0:42 Cut old pins with angle grinder. These are pinned over so no other way than cutting.
1:11 Electrolysis bath : water and sodium carbonate solution, parts connected to negative side and steel sacrificial anodes to positive sice of a DC power supply (car battery charger). 2-3 hrs at 10amp.
2:00 Scribe tang center line.
2:03 Drill more and larger holes for the aluminum to grab.
2:31 High density foam (used for home insulation).
2:39 Hot wire foam cutter machine.
3:10 Glue foam scales with hot glue.
3:40 Regular white plaster mixed with water and brushed on foam to help with cast quality.
4:16 Fine sand for the lost foam mold (I'm using burned out petrobond sand but any fine and dry sand would work).
4:39 Molten aluminum.
4:52 Adding sodium carbonate as degassing agent and "lite salt" (a mix of potasium cloride and sodium cloride) as flux.
8:22 Cut sprue with metal cutting bandsaw.
9:04 A lot of rasp work... A lot! Aluminum is so abrasion resistant.
9:40 Handle shape is pretty sharp to accentuate the contrast between old blade and new handle.
10:18 Hand sanding from 80 to 1200 grit.
10:42 Polish with fine polishing compound on cotton wheel.
10:57 Cold blue on the tang to get even more contrast between steel and aluminum.
11:24 Re-grind bevels and sharpen on 2x72 belt grinder.
11:50 Edge strop on leather with fine polishing compound.
Thanks a lot for watching, I hope you liked the video!
Suggestions and comments are always welcome.
Leave a like and share to anyone who might be interested! Thank you!!!
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blackbeardproject.com/
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[@BlackBeardProjects]

Check description for detailed list of operations and all product used. If you like what I do consider supporting me so I can keep on making, join as channel member or check my Patreon for early access and voice-over edit of my videos. Thank you!

[@anthnylder8136]

hi mr. beard

[@ale5404]

next time do a Katana

[@BlackBeardProjects]

Ah! I paid 5€! Excellent deal.

[@drecnark]

Black Beard Projects I would like to buy the cleaver or find one for me I am cook and knife collector heheheh

[@davidduffy6685]

The bevel is incorrect, but I think you know that.

[@anthnylder8136]

I love that you don't play music like other restorers (Is that even a word?) do.

[@bentarr17]

Oh boy. You need to start watching My Mechanics. Also Rescue and Restore as well as TysyTube.

[@lurezpe8655]

And restore It, hand tool rescue

[@anthnylder8136]

@@bentarr17 @lur ezpe thanks for the recommendations yall

[@hummeros]

because that sounds are just a type of asmr!

[@microstrat]

If you close your eyes you can hear Jimmy diresta...

[@reinerhudson]

I really don't like metal handles, I prefer the wood ones.. but your job was impeccable as always! cheers

[@DimNussens]

Me neither, but I did like that he kept in the fail castings as well as the final successful one. I like to see how things go wrong just as much as seeing them go right.

[@reinerhudson]

@@DimNussensI totally agree

[@BigBossBernie]

@@DimNussens this - of course there will eventually be a successful casting, but what we can learn most from are failures, so thanks for not omitting them :)

[@RawG4M3R]

i agree a million times

[@elsenorputoamo1743]

Can you tell me some yt channels of wood ?

[@HappyHands.]

By #3 i was like..."Dude.. just make a wooden handle" Glad you stuck with it.

[@kilroym1a1]

All these pour fails are trying to tell you DO NOT USE AN ALUMINUM HANDLE!

[@johnx9955]

No

[@HandToolRescue]

Ah, the old shovel knife!

[@MargulpKano]

Even if i’m not a huge fan of metal handles i have to admit that this is quite cool, because it contrasts perfectly with the dark blade itself, good job!

[@valerie2842]

I love that you left the bulk of it black and that there are just a couple of things that are super shiny. It's very striking and unique. Great job!

[@garymucher9590]

How about a compromise, polished metal bolsters with quality wooden handles.

[@axymandchorus1157]

as said in description its just for fun - man loves casting metal so he does it no matter how impractical it is

[@jaime1057]

Yor mom iz miy girfrend

[@h...........................]

@@jaime1057 **shows reverse Uno card**

[@nonfique429]

- please don't make alu handle _sees styrofoam_ - ah shit here we go again

[@BlackBeardProjects]

Ahah!!

[@gubr]

Could have been copper this time. As a little surprise..

[@nonfique429]

@@BlackBeardProjects still a great job nonetheless! turned out looking great and I believe that was your aim.

[@bearox8302]

Black Beard Projects hahaha dude you really gotta leave that thing everyone is hating It

[@kenwaid8239]

I like his handles as they are not thick and clunky, this one came out great.

[@tswrench]

They used to use cleavers like that for butchering Brontosaurus's to feed the town of Bedrock.

[@stepcorngrumbleteats7683]

And if Crocodile Dundee would see that coming out from your jacket, he'd poop his pants...

[@JudgeDredd_]

True

[@richardharepax123]

Run dino run

[@FrenchGuyCooking]

Really cool restoration. The blade feels very much like an ol' butcher meat cleaver. I've seen some very similar in the uk.

[@Sludgepump]

Thanks for showing the fails! Always great to pick up experience without going through the failure yourself. Great looking cleaver. Fantastic video as usual.

[@McCulsky]

Love your dedication and improvisation after each fail, as much as I'd love to see a wooden handle on this type of carver. Please keep these videos coming!

[@thunderstruck1078]

Wooden handle beats alu every single time.

[@kat-rau.]

I was hoping he'd make a wooden handle after fail #2. Metal handles just look so tacky.

[@KainYusanagi]

@@kat-rau. They're also terrible for your hand due to metals not absorbing reverberations. We've told him this shit numerous times and he just ignores us. It basically makes these cleavers useless for any real use.

[@yaelbhm9849]

@@KainYusanagi if you had read the description you would know it is a showpiece, it's not meant to be an ergonomic tool

[@KainYusanagi]

@@yaelbhm9849 And I loathe that. This tool still has decades, if not centuries, of life left in it, especially unlike a lot of modern tools. As a cook, it feels like sacrilege to treat a knife this way.

[@Snow-dg7um]

He is free of his choice. do it if its better for you

[@iestbop7848]

Im glad u put the before in the thumbnail so it doesnt spoil the video 😄

[@JK-tm7vj]

Historic tools deserve more respect!

[@SpizawkDaKizowz]

Including your casting failures was the best thing you did in this video. People learn just as much from mistakes (and seeing them) as they do from successes. Probably even more.

[@xPhillMcDx]

Realized you were doing aluminum and was not psyched. Finished it and actually really grew on me!

[@ionuttudor1851]

That skin test was really funny! Nice job!

[@a-ls6333]

It's interesting watching the casting process, but you can't beat a nice wooden handle IMO.

[@TheGxpana]

That DiResta shave test was of another level. Awesome result as usual.

[@roadweary5252]

The second I realized that you were casting a handle I rolled my eyes. I am so over people doing that on KZbin. But as I watched, I have to say that I am glad I hung in there. It actually looks really good - maybe because it’s not brass? Well done, sir

[@rickpalechuk4411]

Nice, however I think wood would have been more attractive. Thanks for sharing, Cheers

[@buttermonkeyFTW]

You should do a resin/wood handle soon! They look really nice on knives

[@bolobre4th]

Very nice of you to show the failed attempts as well. It's inspiring.

[@stisher]

Man you deserve a like and a comment. Great persistence.

[@itsMido2]

THANK YOU for showing us the fails.

[@DeadlyPants1404]

I got super excited wen i saw the foam come out for a handle pour!! Keep doing those whn you can love to see it!

[@GooseGosselin]

I almost didn't watch this, so glad I did! One of my favorites! Thank you.

[@claybaker8467]

Your problem with the casts was that you weren’t making the 2nd hole for the release of the gasses to ensure a continuous flow through the mold. The 3rd time you made the second hole but you poured some of the aluminum down it blocking the gasses from escaping properly which is why a portion of the handle did not fully cover the tang of the cleaver. Try pouring it through the first pour spout until you see the aluminum rise up from the second. This will greatly improve you chances for a successful pour

[@CytoplasmicGoo]

I love your videos, but I don't understand the metal scales. I'm assuming its to show us how casting metal is done. But still, slick metal handle with zero traction and shock absorber on a super heaving cleaver is just silly and bordering on offensive. With a little moisture from blood or sweat that thing is flying out of your hand three stooges style. But I'm still watching your videos as they come out, you are an awesome craftsman.

[@evanshoulders3674]

Michael Manalang how is that offensive, your sensitive as hell

[@RussianBreed]

Yea that's the kind of cleaver, that killer butchers use. I"m glad youtube recommended this to me.

[@NilsRohwer]

The handle is incredible. So cool!

[@curlywolfone]

I know this really burly butcher here in Texas that would greatly appreciate that cleaver. He has hands as big as bears paws. As usual; well done.

[@unclefuddelmer9224]

Beautiful aluminum handle on your clever restoration Sir !

[@AwesomeRestorations]

Really loves your project m.r. Black beard. You have very good skills 👌 cool projects. Thumbs up for you 👍

[@AwesomeRestorations]

And by the way. This is a Badass cleaver 😮👍

[@samambrotv]

That monster is for cleaving through bone. Brutal. Fantastic restoration! Thank you!

[@stephanedenis5394]

Nice work !! The aluminum handle has a whole look. Between the old and the modern.

[@zeka984]

You are one persistent fellow 😁 Great job!

[@worseforwearrestoration924]

My night time watching sorted 👌 btw I love that you include fails in your video to really show the process, I think too many get wrapped up in looking perfect, this was great and came out fantastic. Can't wait for the next video 👍

[@reedpiersons177]

Nordic battlefield on the blade would have been cool! Well done sir.

[@tonycee1670]

This dude isn’t afraid to get his hands dirty

[@BigAssGopnik]

Or broken by vibrations

[@alirm849]

Man do not listen to these haters. You are just awesome 👏, it’s so fun watching your videos, and the things that you are restoring is like OMG. Keep it up bro

[@TheDevilOfKimon]

Great Job Black..10/10

[@shadowfang269]

watching your videos is so satisfying

[@huseyinayhan33]

Best restoration video I've seen

[@FairlyOddball]

Great for chopping wood. But if you are going to use it for a meat cleaver, you will need to smooth out the blade. That pitted surface is a paradise for bacteria.

[@mehere8299]

My Name is Nobody It's funny how guys who restore kitchen knives and cleavers never consider that very important point. Also, a knife should have an ergonomic handle. Tools are meant to be used; they should at least look the part.

[@danjing2961]

There was a very ornate large Japanese knife, highly detailed design on the handle and extended into an engraving on the blade; in an ad for a knife convention or something on the video before this one 😬

[@robertgray9802]

I can watch your videos all day you are immensely talented and you don't give up easy as demonstrated in your video

[@justsomebaby3465]

Nothing wrong with a wooden handle once in a while.

[@robkling2243]

I just love these videos, how its re-made. I cant imagine anyone mass producing a handle like that.

[@DerekFromMalden]

OMG I love this. Over the top!! Great Work!!!❤️

[@davidallred9143]

Amazing. The aluminum handle turned out way better than I thought it would!!

[@joralte5600]

Sharing even your failures. That's real honest and the reality. Thanks for sharing. 👌

[@FranksShed]

Awesome Bro! Beautiful come out! Next time you have a badass blade like that, I'd love to do a special handle for it!! 😎🔥💯

[@mavos1211]

When I first see you cast the handles I thought what the hell are you doing but after seeing them finished they look awesome. Great job.

[@Detman101]

Goodness gracious!! That thing is a BEAST!!

[@marylewter9789]

Nice job. Love it. It's big, bad, and sharp.

[@ScrapMetalTherapy]

Hey bro! As always great restoration! You know, I don't have much time doing my own ones, so I watch you work and it also inspires me in doing stuff in my workshop! Good luck!

[@ouou-db9pw]

Ain't nothing more easier than polishing up at old blade that's already been designed. That's nothing more than a janitor.

[@matthubsher4500]

i usually dislike the aluminum cast grips but this one is gorgeous. was hoping for more design than just mirror sheen but this still does it for me

[@derrickcordick1315]

That Is awesome and I love how you are not afraid to show the fails

[@microstrat]

Thank you for sharing also the failures. The shiny aluminum is beautiful.

[@RedBeardOps]

Total Monster!

[@bravo_the_broken4003]

I had my doubts, but this came out awesome

[@bobjoncas2814]

..another one brought back to life, in time to get to work...lol..great vid..

[@EphemeralRage]

That thing is a beast! Great job!

[@edrooney1967]

Superb handicraft and the perfect tool to cut up really big beasts like a mammoth ... or for convenient leg shaving.

[@massimoserra4787]

Great job, this cleaver will do his work other 50 years ;)

[@sushipaolo]

Beautiful work!

[@DaleDix]

The presstube channel is a good example of casting. You could hack someones arm off with one chop of that thing! Good job. The electrolysis never fails to amaze me.

[@Kindiah]

I'm surpassed surprised you didn't give up on making the aluminum handle

[@mandoarevee7578]

Blade that removes leg hair. That's so NEET!! 😜😂

[@TheLupulalb]

Never, but never will I use a metal handle on a cutting tool, the wood for me is .... holy!

[@Gizzmoo420]

Castings failed due to no vent hole for air to escape from

[@jonreno4389]

No. You will redo it with proper scales. This beautiful cleaver demands it. 😭

[@Thumper1968]

Beautiful work, man. Amazing.

[@rafael9910]

Beautiful handle. Special touch.

[@paulolucci7935]

An amazing restoration!

[@jackrock1313]

Excellent work 👍👍

[@JustinTheBoss96]

Every time I see the notification that he uploaded a video I know I'm gonna see something badass that I've never seen before

[@nicholascastillo2029]

You should definitely make a video on creating a sheath for this beauty.

[@turanoguz435]

Why we are always obliged to see every restorator’s hairy arms or legs 😀

[@Piterworkshop]

hahahahahaha one day we will see a tragedy

[@artbowman28]

would you prefer seeing their Hairy Ass??

[@artbowman28]

why would you even go there??

[@MOOEYSMITH]

That's not him. Its his tame yeti.

[@mulls9281]

I really like the look of that alu handle.

[@ScrewsAndTools]

Hello! Well done, but I preferred a wood handles and bronze rivets. Also, I saw an axe butt have dents from blows I guess. Good luck and thank you for sharing.

[@gustavoaffonso6397]

Very nice work.

[@j.s.foster1378]

THAT WAS AWESOME!!! badass man 👍👍

[@alexmercer1875]

Looks cool and all but im really wondering how brittle that tang is now. Its probably pretty brittle now after basically dipping it in molten metal 4 times. Hopefully its still good though. Nice finish

[@homedaily6570]

That's not a knife, this is the knife!

[@TheRedhawke]

Dang bro, now that's a chopper. Love it.

[@sudsy18]

Not going to unlike it, because you clearly stated in the description that you enjoy this form of handle making. Seems like a ton of resources for a “restoration”. Having said that, I’m jealous of that cleaver steel and love your videos, even though I’m on the fence for this one. Regardless, keep em coming!

[@wolveold]

Great! You've got two!

[@namorrison1979]

Beautiful work as always was wondering about the aluminium handle, just curious.

[@brasilvirals]

Hello, I make knives here in Brazil, great video, but because it is a cleaver, the cutting geometry would be more appropriate in convex and with greater cutting angle. I would anneal the metal after that, selectively quench using the Japanese clay method, leaving the hard cut and soft back, not tempering, yet could make the hamon reveal beautiful.

[@dougleshemmer8654]

If it's a chopping tool why not temper dosnt that run the risk of cracking or breaking

[@brasilvirals]

​@@dougleshemmer8654 i use japanese method with clay, the back of the knife goes soft, so no need to temper, when i use method western i temper

[@lamproknives]

@@brasilvirals every single method of quench needs to be followed with a temper. Else your edge will chip or crack

[@brasilvirals]

@@lamproknives Aprenda a pronunciar I disagree, katana is no tempered and have you ever seen a break? this week I sold a Japanese chef's knife with untempered cleaver geometry and was tested on bones, and the wire remained untouched, I have experience because I make blades. I say, you can make blades without tempering even if they are hardened in water, the western method of hardening the whole blade makes no real sense no need

[@brasilvirals]

@@lamproknives our talk will give a metallurgy essay heheheheh

[@sonyhk3824]

Beautiful work

[@davidfinn3771]

Excellent. Great to see skill's like that

[@easydiy6862]

Hello, I'm from Thailand, I like your video.

[@MikeUman]

That thing belongs in a movie like "Silent Hill." 😱

[@Mj-yh2vb]

Having a love-hate relationship with this one sir lol

[@spetsnaz1014]

Aluminium handle!!!! You'll be building an underground hut with swimming pool next.