Casting the punch dagger I can't spend $1000 for a real Robbins of Dudley knife to melt down to see how they did it back in the day. So, this is what I came up with.

The all aluminum pattern with the blade and armature for finished knife The lower part of the mold packed around the pattern and the sand cut down. Packing the sand in the top part of the mold. Gently removing pattern after cutting gate and runner Pattern replaced with blade and handle armature Cutting the sprue using a 1 1/4" brass plumbing tailpiece The mold's finished ready to be put back together. The metal's poured. Now we play the waiting game. The rough casting, just as it comes out of the sand.