Knife making safety: the kit and habits that matter

Knife making safety comes down to five hazards: dust in your lungs, things in your eyes, belts and drills grabbing you, carbon monoxide from gas forges, and fire from quench oil. The kit that handles all five costs less than a set of good files. The habits cost nothing.

This guide is for anyone setting up a first workshop, whether you're filing in a shed or running a forge and a 2x72. It covers what to buy, what each item actually protects against, and the habits experienced makers follow without thinking.

It isn't a substitute for a manufacturer's manual or proper training. If you can, learn the grinder and forge on a course before you use them alone.

Knife making safety at a glance

Cost ranges are rough estimates for Oct 2026; Amazon prices aren't shown on this site because they change daily.

What are the biggest risks in knife making?

Ask a room of makers about injuries and you'll hear the same stories. A blade snatched by a buffer and thrown. A belt that broke and knocked someone's glasses off. A finishing room full of carbon monoxide from the forge next door. Those three come straight from an American Bladesmith Society safety thread and a CO discussion on the same forum (ABS shop safety; ABS carbon monoxide).

Most knife making injuries aren't cuts from the finished knife. They come from the machines and the heat. The long-term risk is quieter: years of breathing fine dust.

Which respirator do you need for G10, micarta and wood dust?

You need a reusable half mask with P3 filters (UK/EU) or P100 filters (US). A paper dust mask isn't enough.

G10 is glass fibre set in epoxy resin. Micarta is cloth or paper set in phenolic resin. Carbon fibre is similar. Grinding them makes fine, sharp dust, and makers on BladeForums treat it as a real lung hazard: use a half or full-face respirator, grind or sand wet, and clean up with damp rags and a HEPA vacuum (BladeForums).

Wood dust is regulated in UK workplaces for good reason. The HSE says wood dust can cause asthma, and hardwood dust can cause cancer, particularly of the nose. The UK limit is 3 mg/m³ for hardwood and 5 mg/m³ for softwood over 8 hours (HSE wood dust). Many handle woods are exotic hardwoods.

P3, P100, FFP3: what do the ratings mean?

Sources: European respirator standards; NIOSH filter ratings.

For knife making, P3 or P100 on a half mask is the sensible standard. FFP3 disposables are fine for short jobs, but they're more expensive per hour and fit varies.

Getting a respirator to actually work

• Fit matters more than the filter. The HSE says tight-fitting masks should be face-fit tested and worn clean-shaven (HSE). A beard breaks the seal.
• Change filters often. Ed Caffrey's advice on the ABS thread is to change them frequently (ABS). Do it when breathing gets harder, or by the maker's guidance.
• Wear it for cleaning up too. Never sweep dust or blow it off with compressed air; the HSE says both throw it back into the air. Use a vacuum that meets at least Class M (HSE).
• Sand G10 and micarta wet where you can, and keep the dust off your skin and clothes.

See our respirator guide for fit testing, beards and powered respirators.

How should you protect your eyes and face?

Wear impact-rated goggles or safety glasses every time a machine runs, and add a face shield at the grinder.

On the ABS safety thread, makers describe belts breaking and knocking glasses off, and wearing a hat to protect the face from broken belts (ABS). Everyday glasses aren't impact-rated.

What to look for:

• UK/EU: EN 166 marking. The impact letter tells you the rating: F is low energy (up to 45 m/s), B medium (up to 120 m/s), A high (up to 190 m/s). K means scratch-resistant and N anti-fog (JSP).
• US: ANSI Z87.1 marking ("Z87+" for high impact).
• Goggles over prescription glasses, or prescription safety glasses.
• A face shield over goggles at the belt grinder and angle grinder. Shields alone aren't primary eye protection.

Do you need hearing protection?

Yes, for any grinder and for long hammering sessions. UK workplace rules require hearing protection to be provided and used where daily exposure exceeds 85 dB(A) (Healthy Working Lives). A belt grinder or angle grinder in a small shed will get you there.

Ear defenders are easier to take on and off than plugs, and they work over a respirator strap. Many makers wear both for long grinding sessions.

Is it safe to wear gloves at a belt grinder?

This is the most argued-over question in knife making safety, so here's both sides.

The case against gloves near moving parts: a glove can catch and pull your hand in. The HSE prosecuted a West Midlands firm after a worker's gloved hand caught in an unguarded pillar drill bit; his arm was pulled round, breaking two bones. The HSE said the injury could have been prevented by not wearing gloves, guarding the bit, and training (ISHN, 2016).

The case for: some grinder manuals tell you to wear gloves to protect from sparks and heat (Oregon 760 manual), and one ABS poster recommended gloves for heavy coarse grinding (ABS).

Our view: no loose gloves near a belt, a drill bit or a buffer. The belt takes the glove before you can let go. If the steel is too hot to hold, dip it in water more often, or hold it with a clamp or a magnetic holder.

Belt grinder safety: the rules that prevent most injuries

• Keep the work rest tight to the belt: no more than about 3 mm (1/8"), so thin work can't be dragged into the gap (Oregon 760 manual; OSHA 1910.215 via Industrial Monitor Direct).
• Never point the edge into the direction of belt travel. Grind with the edge trailing or facing up, so a catch throws the blade away from you rather than into the belt.
• Hold small parts in a clamp or holder, not your fingertips.
• Tie back long hair, remove jewellery, avoid loose sleeves (Oregon 760 manual).
• Check tracking and tension before each session. A belt that wanders off the wheel can snap or come off.
• Keep sparks away from wood dust. Steel sparks landing in wood dust in a bin or extractor can start a fire. Vacuum the grinder base daily, and keep flammable liquids away (Oregon 760 manual).
• Respect the buffer. It is the machine most likely to snatch a knife and throw it. Work on the lower half of the wheel with the edge pointing down and away, and never buff towards a sharp point or edge.

Pillar drills: clamp the work in a drill vice or against a stop. Work that spins on the bit will cut you (KnifeDogs).

Forge safety: carbon monoxide, ventilation and gas

Why you need two CO alarms

Carbon monoxide has no smell. Gas and coal forges both make it, and a forge running rich makes more.

The ABS forum records that a smith, Joe Hobart, died of CO poisoning from his gas forge, and another suffered brain damage. Kevin Cashen describes the detectors in his forge area staying silent while the adjoining finishing room reached dangerous levels (ABS).

So:

• Fit at least two alarms: one in the forge area and one in any room next to it, especially a room where people rest or work for long periods.
• Buy certified alarms. UK: BS EN 50291 (Public Health Wales). US: UL 2034 (In Compliance).
• Test them before each session.
• Know the symptoms: headache, dizziness, nausea, breathlessness, collapse. If you feel any of them while forging, shut the gas off, get into fresh air and seek medical advice (Public Health Wales).

Ventilation

Bladesmiths use roof-peak extract fans, wall openings and open doors (ABS). Coal forges need a chimney (Make:). A shed with the door shut is the worst place to run a forge.

Propane bottles, regulators and hoses

• Store propane outdoors, upright, away from drains, doorways and ignition sources, and never below ground level (Calor).
• LPG is heavier than air. It sinks, runs along the ground and collects in drains, gullies and cellars (HSE LPG advice via East Cambridgeshire DC). A pit or low floor near a forge is a trap.
• Use the right regulator. Most forges need an adjustable high-pressure regulator (often 0–4 bar in the UK; 0–20 or 0–30 psi in the US), not a 37 mbar barbecue regulator. EU forge regulators don't fit UK propane bottles; replace rather than adapt (BushcraftUK, 2017).
• Use a long enough hose to keep the bottle well away from the forge. One UK maker judged a 1 m hose too short.
• If you smell gas: close the bottle valve if it's safe, open doors, and don't switch electrics on or off (HSE LPG advice).

Seal the forge lining

Cheap gas forges are lined with ceramic fibre blanket. Unsealed fibre sheds fibres you breathe; one iForgeIron veteran puts it bluntly: cover the wool with refractory "unless you want to develop silicosis or mesothelioma in 20 years" (iForgeIron). See sealing a gas forge.

What to wear at the forge

Natural-fibre clothing (cotton, wool, denim), because polyester can melt onto skin, plus a leather apron and safety glasses (iForgeIron). Leather gloves are fine here for handling hot stock and tongs.

How do you stop a quench oil fire?

Quench oil flares when hot steel goes in. That's normal. A fire happens when there's too little oil, the oil is too hot, or the tank is wrong.

Set up to prevent it:

• A metal tank with a metal lid, never plastic. The lid smothers flare-ups. Keep it within reach (iForgeIron).
• Plenty of oil. An old rule of thumb is about 1 gallon per pound of steel (roughly 8 litres per kg), and "too much is better than too little" (iForgeIron). A tank at least 150 mm (6") deeper than your longest blade lets you submerge it fully (BladeForums).
• Warm, not hot. Most quench oils are used around 50–65 °C (120–150 °F) (Knife Steel Nerds). Keep far below the oil's flash point; flash points of common quench oils run from about 210 °C to 300 °C (413–580 °F) on one forum list.
• Stand the tank on something that won't burn, with a tray or larger container to catch spills.
• Quench with long tongs, submerge the blade fully and quickly, and open the lid away from your body.

If it catches fire:

1. Put the lid on.
2. If that fails, use an extinguisher rated for flammable liquids (Class B): foam, CO2 or dry powder (Warwickshire Fire and Rescue).
3. Never use water. Burning oil floats on water and spreads, and water flashing to steam under hot oil can throw burning oil out of the tank (Safelincs).

See quench oil: which one to buy for oil types and speeds.

What should be in a knife making first aid kit?

Keep a kit on the wall by the door, not in the house.

• Sterile dressings and pads for cuts. Press firmly on a bleeding cut for several minutes and raise it above the heart. Go to an emergency department if the bleeding won't stop, spurts, or you lose feeling or movement (NI Direct).
• Cling film for burns. Cool a burn under cool running water for at least 20 minutes, then cover loosely with cling film. No ice, butter or creams (Queen Victoria Hospital NHS).
• Eye wash and eye pads. Rinse loose grit from the inner corner; leave anything embedded and get to an eye casualty unit (St John Ambulance).
• A phone in reach. Especially if you work alone.

Ten habits that matter more than any kit

1. Goggles on before the machine starts, off after it stops.
2. Mask on for any handle material, and for clean-up.
3. No gloves near belts, bits or buffers.
4. Work rest within 3 mm (1/8") of the belt.
5. Edge never pointing into the belt's travel.
6. Forge door open; CO alarms tested.
7. Gas bottle outside; check the hose.
8. Lid beside the quench tank; Class B extinguisher by the door.
9. Vacuum, never sweep.
10. Stop when you're tired. Most accidents happen at the end of a long day.

Get the printable workshop PPE checklist, and see CO alarms and ventilation for placement diagrams.

FAQs

What PPE do I need for knife making?

At minimum: impact-rated goggles or safety glasses, a half-mask respirator with P3 (UK/EU) or P100 (US) filters, ear defenders, and a leather apron. Add CO alarms if you use a gas or coal forge, and a foam, CO2 or powder extinguisher if you quench in oil. Most of this costs under £150 or $150 in total.

Is G10 dust dangerous?

Treat it as dangerous. G10 is glass fibre in epoxy, and grinding it makes fine, sharp dust. Makers recommend a proper half or full-face respirator rather than a paper mask, sanding wet where possible, and cleaning up with damp rags and a HEPA or Class M vacuum. Micarta and carbon fibre deserve the same care.

Do I need a CO alarm for a propane forge?

Yes. Gas forges produce carbon monoxide, which has no smell, and smiths have died from it. Fit an alarm in the forge area and another in any adjoining room, because CO can build up next door while the forge area alarm stays quiet. In the UK buy BS EN 50291 alarms; in the US look for UL 2034.

Can I use a forge in my garage or shed?

Only with real ventilation: open doors, an extract fan high up, and CO alarms. Keep the propane bottle outside, use a long hose, keep the forge clear of anything that burns, and never forge in a closed shed. Check your home insurance and any tenancy or local rules before setting up.

What fire extinguisher do I need for quench oil?

One rated for flammable liquids (Class B): foam, CO2 or dry powder. Never use water on burning oil, because it spreads the fire and can make the oil erupt. Your first line of defence is a metal lid on the quench tank, which smothers most flare-ups.

Should I wear gloves when using a belt grinder?

We say no. Gloves can be caught by a moving belt, bit or buffer and drag your hand in. Some grinder manuals say otherwise, so check yours, but most experienced makers grind bare-handed and cool the steel often. Wear leather gloves at the forge, where nothing spins.

How do I know if my respirator fits?

Do a seal check every time: cover the filters and breathe in, and the mask should pull in slightly and hold. In a workplace, tight-fitting masks should be face-fit tested. A beard or stubble breaks the seal, which is why the HSE says wearers of tight-fitting masks should be clean-shaven. If you keep a beard, look at loose-fitting powered respirators instead.

Sources

1. ABS forum, shop safety topic (Sept 2012): https://www.americanbladesmith.org/community/general-bladesmith-discussions/shop-safety-topic-for-september-2012/
2. ABS forum, dangers of carbon monoxide in the shop (2016): https://www.americanbladesmith.org/community/general-bladesmith-discussions/dangers-of-carbon-monoxide-in-the-shop/
3. BladeForums, how dangerous is G10 dust: https://bladeforums.com/threads/how-dangerous-is-g10-dust.1040385
4. HSE, wood dust: https://www.hse.gov.uk/Woodworking/wooddust.htm
5. European respirator standards (EN 143, EN 149): https://en.wikipedia.org/wiki/European_respirator_standards
6. NIOSH air filtration ratings: https://en.wikipedia.org/wiki/NIOSH_air_filtration_rating
7. JSP Safety, EN 166 markings: https://jspsafety.helpjuice.com/en_GB/what-do-the-numbers-and-letters-shown-on-spectacles-goggles-and-visors-mean
8. Healthy Working Lives (Public Health Scotland), noise precautions: https://healthyworkinglives.scot/workplace-guidance/health-risks/noise-hearing-loss/Pages/precautions.aspx
9. ISHN, "When a glove does not enhance workplace safety" (2016): https://ishn.com/articles/104903-when-a-glove-does-not-enhance-workplace-safety
10. Oregon 760 belt grinder manual: https://www.trick-tools.com/common/documentation/or_760_manual.pdf
11. Industrial Monitor Direct, closing the work-table gap: https://industrialmonitordirect.com/blogs/knowledgebase/discbelt-grinder-safety-closing-the-work-table-gap
12. KnifeDogs, most common beginner mistakes (2011): https://knifedogs.com/threads/most-common-mistakes-that-beginners-make.15486/page-2
13. Public Health Wales, carbon monoxide: https://phw.nhs.wales/topics/carbon-monoxide
14. In Compliance Magazine, UL 2034 revised: https://incompliancemag.com/ul-2034-for-standard-for-single-and-multiple-station-carbon-monoxide-alarms-revised/
15. Make:, blacksmithing basics: https://makezine.com/article/workshop/blacksmithing-basics/
16. Calor, storing gas bottles: https://www.calor.co.uk/gas-bottles/advice/storing
17. HSE LPG cylinder advice (East Cambridgeshire DC copy): https://eastcambs.gov.uk/sites/default/files/2024-09/Small%20scale%20use%20of%20LPG%20cyclinders%20advice%20notes.pdf
18. BushcraftUK, UK propane regulator for an EU forge (2017): https://bushcraftuk.com/community/goto/post?id=1836964
19. iForgeIron, ITC-100 vs Plistix vs Satanite vs Mizzou (2011): https://www.iforgeiron.com/topic/24282-itc-100-vs-plistix-900f-vs-satanite-vs-mizzou/
20. iForgeIron, beginning bladesmithing: buy or build a forge: https://www.iforgeiron.com/topic/68003-beginning-blade-smithing-buy-or-build-a-forge/
21. iForgeIron, how much quench oil to use: https://www.iforgeiron.com/topic/61151-how-much-quench-oil-to-use/
22. BladeForums, quench oil: https://www.bladeforums.com/threads/quench-oil.1745350
23. Knife Steel Nerds, which quenching oil is best (2021): https://knifesteelnerds.com/2021/07/19/which-quenching-oil-is-best-for-knives/
24. Warwickshire County Council, fire extinguishers: https://www.warwickshire.gov.uk/fireextinguishers
25. Safelincs, fire extinguishers and flammable liquid fires (2026): https://www.safelincs.co.uk/blog/2026/05/06/fire-extinguishers-and-flammable-liquid-fires/
26. NI Direct, cuts and grazes: https://nidirect.gov.uk/conditions/cuts-and-grazes
27. Queen Victoria Hospital NHS, burns first aid: https://www.qvh.nhs.uk/?p=804
28. St John Ambulance, eye injury: https://www.sja.org.uk/first-aid-advice/eye-injury/
29. Screwfix, 3M 6502QL A2-P3 kit: https://www.screwfix.com/p/3m-6502qlkit-1-one-size-quick-latch-half-face-respirator-kit-with-replaceable-filters-a2-p3-7-piece-set/801EJ