In Austin, where outdoor culture meets culinary creativity, having a reliable custom knife isn’t just a luxury—it’s a tool many locals rely on daily. Whether you’re a hunter, chef, or knife enthusiast, knowing when it’s time to retire your blade can save you time, effort, and even safety concerns. Christopher Lee Jaramillo of Apache Knifeworks, a Texas-based custom knife maker, offered expert insights on when to let go of an old favorite. As he put it, “In all honesty it’s going to be based off how much it’s used and what for…” Let’s look at five key signs that it may be time to upgrade.
1. Deep Rust That’s Gone Beyond the Surface
Rust is common, especially in carbon steel knives, but not all rust is equal. When oxidation digs deep into the blade, it can compromise the steel’s structural integrity. Jaramillo warns, “…if the rust is deeper than just the surface it might be time to get a new one…” Surface rust can often be cleaned, but deep pitting can lead to weakening and cracks. “Is deep rust on a knife dangerous?” Yes—if it’s more than just cosmetic, it’s a safety risk.
Risks Of Using A Rusted Blade
- Health risks: Rust is essentially iron oxide, and while small amounts aren’t inherently poisonous, deep rust often harbors bacteria. If that rusted metal contacts food, especially open cuts or moist ingredients, it can introduce harmful pathogens that may lead to foodborne illnesses or infections.
- Risk of injury: A rusted blade is usually weaker and more brittle. It can snap or chip unexpectedly during use, causing sharp fragments to fly or the knife to break mid-cut, leading to cuts or puncture wounds.
- Poor performance and control: Rust creates rough, uneven surfaces, which seriously affects the sharpness and balance of the knife. A dull or uneven blade requires more force to cut, making it much easier for the knife to slip and cause accidental injury.
- Potential for tetanus: Although the risk is relatively low from kitchen use compared to, say, rusty nails outside, a deep cut from a heavily rusted knife could still pose a risk for tetanus, especially if your vaccinations aren’t up to date.
2. Cracks or Structural Damage to the Blade
Even a minor crack in a knife’s tang (the portion of the blade that extends into the handle) or in the blade itself is a serious issue. These flaws can grow over time, especially under pressure. Jaramillo advises, “Cracks in the tang or center of the blade or excessive bends would be something to consider…” If your blade flexes oddly or seems brittle, don’t ignore it.
When is a cracked knife unsafe to use?
A cracked knife becomes unsafe to use as soon as the crack compromises the blade’s integrity — and honestly, that’s almost immediately after the crack forms. Here’s why:
- Structural weakness: A crack, even a small one, creates a weak point where the blade can snap suddenly under pressure. Cutting something tough (like squash, frozen foods, or meat with bone) could cause the blade to break mid-slice, leading to serious injury.
- Unpredictable performance: Cracks affect how force is distributed along the blade. This makes the knife behave unpredictably — it might slip, flex oddly, or twist during use, which can easily lead to accidents.
- Hidden rust and bacteria: Cracks, especially fine ones, are almost impossible to clean thoroughly. This can turn the knife into a breeding ground for bacteria, even if it looks “clean” on the surface.
- Handle and blade separation: Sometimes a crack extends into the tang (the part of the blade that goes into the handle). If that happens, the blade could separate from the handle unexpectedly while you’re using it.
If you notice a crack — especially one that’s longer than a few millimeters, or if it’s near the middle or spine of the blade — retire the knife immediately. It’s not worth the risk.
3. “You’ve Sharpened Beyond the Spanish Notch“
Custom knives often include design cues to help track their lifespan, like the Spanish notch. According to Jaramillo, “Sometimes people say if you have sharpened past your Spanish notch it’s probably time to get a new knife because that’s a pre-determined spot for how much usable steel you can sharpen to…” Once you’ve gone past that notch, you’ve likely lost optimal blade geometry and cutting performance.
What does sharpening past the Spanish notch mean?
Sharpening past the Spanish notch” refers to accidentally grinding or honing the edge of a knife into or beyond the small, often crescent-shaped cutout found at the base of the blade—typically on traditional knives like Bowie knives or some fixed blades.
Here’s what that means in detail:
- The Spanish notch (also called a “choil” in some contexts) is a small decorative or functional notch near the heel of the blade. Its original purpose is debated—some say it helped catch an opponent’s blade in combat, while others argue it’s purely decorative or meant to visually separate the sharpened edge from the ricasso (the unsharpened part of the blade near the handle).
- Sharpening past it means you’ve ground the edge deeper than the intended cutting surface, into or through the notch, possibly altering the blade’s profile.
Why it’s a problem?
- Structural weakening: Sharpening into the notch can create an uneven edge and stress point that may cause the blade to chip or break more easily at the base.
- Ugly or uneven grind: It often results in an inconsistent edge that doesn’t follow the original blade geometry, which affects cutting performance and aesthetics.
- Shortens knife life: You’re effectively eating into the usable blade more quickly and reducing the amount of future sharpening the knife can handle.
Some users actually grind off the Spanish notch entirely to avoid this issue, especially if they regularly sharpen with belt grinders or guided systems that don’t accommodate that gap well.
4. Blade No Longer Holds an Edge
If your knife dulls quickly—even after proper sharpening—it may be due to metal fatigue or low-quality heat treatment in older blades. Over time, repeated sharpening wears away steel that no longer supports a proper edge. This leads to a knife that feels sharp for a day, then struggles the next.
Why won’t my knife stay sharp anymore?
If your knife dulls quickly no matter what you do, the problem usually comes down to one of these culprits:
- Cheap or worn-out steel – Low-quality blades or over-sharpened edges simply can’t hold a sharp edge for long. Once the steel is too soft or too thin, it folds or chips fast.
- Bad sharpening habits – Using the wrong angle, too much pressure, or overheating the edge can create a weak bevel that dulls after a few uses.
- Wrong cutting surface – Hard surfaces like glass or stone will kill your edge almost instantly. Stick to wood or soft plastic boards.
- Rough usage – Using your knife to pry, hack through bone, or saw frozen foods will destroy even premium blades.
- Skipping maintenance – A honing rod keeps your edge aligned between sharpenings. If you’re not using one, your edge is probably folding over without you realizing it.
5. The Knife No Longer Suits Its Original Purpose
Sometimes, it’s not damage but a mismatch of function. Maybe you’ve moved from field dressing to more detailed carving, or your cooking style has evolved. As Jaramillo mentioned, “In all honesty it’s going to be based off how much it’s used and what for…” A custom knife should suit your lifestyle—not the other way around. If your tool no longer serves its purpose well, it may be time to upgrade.
Signs That Can Be Repaired, Not Replaced
Not every flaw means the end of a knife’s life. Some problems, while alarming, can be fixed by a skilled maker. Jaramillo explains, “…things like broken tip, crack handle material chips can all be remedied…” This is especially true for high-quality knives with sentimental or collectible value. Even a damaged blade can often be reshaped, and “Blade and handle can always be made shorter…” if needed. “Can a broken knife be repaired?” In many cases, yes.
Conclusion
Your knife is more than just a tool—it’s an extension of how you live, cook, or work. Paying attention to these five signs can help Austin residents know when it’s time to retire a blade and invest in something that better fits their current needs. But don’t toss it at the first scratch; as Jaramillo reminds us, some signs are just signs, not a death sentence. If you’re ever unsure, consult a custom knife maker or bladesmith for a professional opinion.
