Saturday, March 16, 2013

DIY blade replacement

Here's a nice step by step guide to show you how to change a broken blade in a way that's very similar to how Victorinox assembles the knives.I already discussed assembling a custom knife, but with screws instead of the original brass pins. This time I use the brass pins. This question was asked a few months ago by one of the visitors here and I made some pictures while doing a repair on one of the Spartans I received yesterday. The main blade and small blade had a broken tip. 

UPDATE : Victorinox gives a lifetime warranty, but normally only for the first owner, who actually bought the knife. Therefor they ask a POP (Proof Of Purchase) when you send in the knife. Some add the box, as they don't have the ticket anymore. If you bought a knife secondhand or received it as a gift from a company (Ad-knife) or just can't wait till Victorinox fixes it for you, you could try this tutorial! You should always try to send it to Victorinox if possible! They keep the knife intact!

Taking off the scales is discussed on another topic and once done you gain access to the rivets wich we're going te reuse afterwards...

Use a small clamp to secure the knife. This helps when you center drill the rivets. These rivet-heads are unique and very hard to find. Try to reuse them! I use a paper towel to keep the knife's side from scratching up.

Center-drilling the small rivets can be done by a 2mm drill for the small rivets and a 2,5mm drill for the larger ones. Use a center-point to keep the drill from "running".

Once drilled deep enough (till you reach the liner) , the heads pop loose and you can start disassembling the knife...

This is the ideal moment to clean all the tools and liners. Here are the damaged blades placed next to the donor-parts. Keep in mind that the donor-blades are used parts. Small scratches can be removed...

Start with peening the pins on one side and lock the rivet-heads in place. Insert the pins in the liner and use a piece of tape to keep 'm from falling out. Now you can start assembling layer by layer. Maybe a smart thing to do before you start disassembling is making a layout so you know afterwards how to put it back together. For me it's a habbit, but my first one was a disaster! ;)

Once the knife's assembled, you need to grind away any excess brass in the rivet-heads. I use some glue to secure the rivets. Not how it should be done, but it assures you that the rivets hold, even when the knife endures some rougher work. 

Put the scales back on. If everything went as described, the scales should snap on and your knife should look as new! 


  1. Great man, I was looking for this information for ages, I need replace the main blade in a swiss champ! nice page!

  2. Very helpful and well-illustrated instructions -- thanks, Jeroen!

  3. Actually, Victorinox will fix and honor its lifetime warranty commitment even if you buy it secondhand :)

  4. Where did you find the brass pins. I cant find them. Please help

  5. Thanks for the tutorial. This will be one of my upcoming winter projects and I was just going to blindly wing it before I saw this.

    I'm actually contemplating doing doing the previously unthinkable, remove the main blade altogether (disarming it) so that I can travel with it more readily making it a Swiss Army tool rather than a "knife". Haven't decided what I'm going to replace it with yet, but I have several tool extras onhand.

  6. Hi Jeroen,
    I was wondering if you knew of any place or way to buy Victorinox blades as a single part.

  7. Thanks for these instructions, very helpful. I would also like to know where you got the brass rivets from. I've done an extensive search and haven't found any.