Full
tang construction is probably the most common design that you're going to
get involved with. It's a little bit less work and most folks will attest
that it's a much stronger design.
Click on any of
the thumbnails below for a more detailed photo
This is what comes in this
very complete kit: shaped nickel silver bolsters, pins for the handle
material and bolsters and thong hole tubing. The onlt thing you need
to provide is your choice of handle material. ( Did I mention that this
knife was gorgeous? )
Speaking of which: I always
wanted to make a stag handle knife, but the embargo from India has made it
very hard to get and VERY expensive. I decided to try a new product called
Imistag (Imitation Stag), a dyed, jigged bone product. I had heard good
things but wanted to see for myself.
For a more custom look, I'm
going to round the front shoulders of the bolsters as shown in this photo.
A nice custom touch that only custom knifemakers add and that will make
your creation stand out from the rest. Factories don't do this
except on very expensive collector's editions. See Step 6
Some people are
never happy, are they? As beautiful as this kit is, I decided to modify it
to get rid of the "thumbs" on the bottoms of the bolsters and
blade. A Mototool with fiberglass cutting disk makes quick work of even
the hardened steel. Be careful though: the bolsters get very hot with this
operation!
These are some of
the nicest bolsters I've seen but you won't always be this lucky. Get into
the habit of flat grinding the inside sides that will face the blade for a
perfectly flat, tight fit. Hint: make sure you do the opposite sides on
each so you get two insides, a right and a left. ( Yes, this is from the voice
of experience ).
Let's round the
front of the bolsters like we talked about a minute ago. Use a pair of
vice grip pliers to line them up and clamp them together firmly. Use the
bench sander and "rock" the bolsters back and forth slowly and
gently to round them. Check your work often to make sure your work is
uniform and vary the pressure from top to bottom as necessary
Finish the front
of the rounded bolsters by switching to a worn belt on the bench sander.
Let's polish the front of them now since it'll be tough to do a nice
polish job on these after mounted to the blade.
Free Space
Normally, you'd
have to drill the bolsters for the bolster pins that are going to hold
them to the blade. You lucked out here again : these are predrilled ( and nicely,
too) . I'll cover making bolsters from bar stock and drilling them for a perfect fit in
the hints and tips section in the very near future.a
a
I use a drop of
super glue to hold the bolsters in place while sliding the bolster pins
in. "Peen" or hammer these. The force of hammering will compress
the relatively soft bolster pins, causing them to expand and really,
really hold the bolsters tight. Make sure they're tight but don't go crazy
and overdo it or you may risk distorting the bolster. You don't have to
pound them perfectly flush. We'll sand these off in a moment.
Back to the belt
sander. I use a 120 grit belt for initial shaping. We're going to round
these, so use a gentle side to side rocking motion, checking your progress
often, making sure your rounding is uniform on the right and left sides
and top to bottom.. (Normally, my left hand would be on the back of the
blade, but it's holding the camera).
When done, the
rounded bolsters should look something like this. Rough finish is OK right
now, we'll do a final finish sanding after we add the imitation stag
slabs. For now, just make sure the shaping is uniform left and
right, top to bottom
a
I've been adding a black-white-black fiber spacer behind the bolster or
guard for years as my personal trademark, just in case many years from
now, I somehow turn into a famous, recognized and well renowned
knifemaking craftsman. Hey, it could happen!