Great post snotpig!
grind first with the coarsest grit. Once you feel the blade grind is about 90% complete, start moving to finer grits.
Tyger, you said you bought some cheap coarse belts, I would highly suggest premium belts (i.e. Norton Blaze), they cut faster and last longer. Like snotpig said, about 90% of time you'll be working with the coarse stuff. Ban said he goes through 15-20 coarse belts for every 1 fine grit belt. I didn't believe him at first, but I'm through my 4th coarsest belt and still on my 1st 120 grit.
Well, when I say that they're cheaper, I merely meant the price, not the quality. I ordered 30 x-weight belts, ranging from 60 to 200 grit. Combined with the 12 Blue Zirconia belts I ordered from Lee Valley, I figure I should be covered for coarse belts.
I just got back from buying a Dremel, with the metal cutting discs, as well as a couple Tungsten Carbide cutter bits, for cutting the knife design free of the stock. As well, I'll be borrowing my buddies 4" x 36" bench sander to help in removing some of the stock from the blade.
I won't be able to do anything until I get the call back from the supplier on what metal they can provide, and of course, the coarse belts come in.
BTW, Snotpig, thanks for the info; I like that small axe and Chefs' knife you made. Very cool! <img src="/ubbthreads/images/graemlins/thumbup.gif" alt="" />
