I made this ulu knife about 10 years ago and it still gets used pretty often. It is solidly built and works great. Today I was looking through some old photos and found this sequence. I though it would be nice to share.
- I transferred my pattern to the blade and started cutting.
- My new hacksaw and blade made the cutting easy
- Second cut on the saw blade
- A big C clamp holds the blade tight to the table
- Five cuts to get the basic outside shape
- Drilling holes with a drill press to cut the hole for the handle
- I tried to get the holes as close together as possible, not going outside the pattern
- More drilling – use oil as a lubricant for the bit to reduce friction – less heat
- Connect holes with hacksaw – requires hacksaw blade removal to fit it through first
- Inner handle is roughed out – outside contour smoothing started
- Outer contours completed with bench sander. Inner contour started with file – slow
- The benchtop sander works great. Round wheel is better than the belt for contours.
- Spindle sander would make inside contours easy. I started with files
- Finished inner contours with sander bit and a drill. Spindle sander would be better.
- Testing the feel of the blade. Nice!
- Benchtop grinder / sander makes the work easy
- The final blade with a sanded finish. Cutting edge was added with a file.
- Be careful!
- Handle scales cut from phenolic material. Probably 3/8″ Micarta or G10
- Drill holes in blade first. Use as a guide for each handle scale. Don’t drill holes for both scales on same side of blade. Flip it over for the second scale.
- With smaller holes drilled first in scales, use drill press with bit matched to brass bolster diameter. Countersink bolsters CAREFULLY. Don’t drill through!
- The screws pull the brass bolsters together and keep the handle scales firmly in place
- Another view of the screws and bolsters
- After the screws are tight, cut off them short with a hacksaw.
- The brass bolsters are smoothed off with the belt sander
- Finished ulu after shaping handle
- Adding walnut oil to the handle darkened it up.
- Ulu knife by Russ McMullin





































