About to make my first Puukko - how to

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Hi,

I have decided to try to make a knife - a traditional puukko. Since I have no chance to heat treat a blade (our kitchen oven goes only up to 300 degres Celsius ;) ) I will be buying a ready-made blade as I suspect that trying to use a hand-hold gas blow lamp is not quite up to that task.

I would only add that my only powered source is Li-ion battery powered drill. I do have a small working bench with vise. I have some basic tools, but will get what will be necessary. Since I am located in Germany I will be getting the components from one online german shop (nordisches-handwerk - I only mention it to give you an idea what components I have acccess to).

What I would like to ask is an advice on what information sources you found helpful when attempting something similar.

thank you in advance :)
 
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I think Shop Talk would be a better fit for this question. Moving it now.
 
Just a quick 'thank you' to Garry for moving this thread here (I somehow missed this sub-forum)

Now I am onto going through all of your suggestions. I will be back with questions later :)
 
I build a lot of Puukko. Here is what I would recommend a new maker with few tools.

Start with a good pre-made blade. The ones from Sweden and Norway are all pretty good. Brusletto has a large variety. Tape up the sharp blade part, leaving the tang and ricasso exposed.

Decide what type handle you want. One piece, three piece, or a stacked construction ( birchbark or leather). The front and back piece are traditionally pieces of reindeer antler, but can be wood, metal, bone, Micarta, etc. There are no rules.

You will need to drill a hole down the handle parts to allow them to fit the tang. The only holes that need to be a snug fit are the one at the blade end, and the one at the tang end. The rest can be a non- snug fit. With all the pieces on the tang, the end should be still sticking out. The pieces don't need to be shaped to their final shape yet.

Once all the handle parts are fitted to the tang, sand and shape the front piece to at least 400 grit sandpaper. This piece can't be shaped easily without damaging the blade after assembly.

Glue the handle parts on the blade with slow cure epoxy ( 1 hour or longer cure time). Rig up some sort of clamp to keep the parts tightly together while the glue cures.
If you put some leather or wood on the jaws of a bench vise and clamp the blade tightly in it, the tang can be worked on in the vertical position. This makes assembly easier.

Once the epoxy is cured for a day or two, cut the exposed tang on the end off about 1/16" (1.5mm) and hammer it into a rounded peened end with a ball peen hammer.

To shape the handle, start with rasps and files, and shape the basic outline of the handle. Refine it slowly, and then switch to sandpaper. Work evenly ands slowly and get the shape that feels good in your handle. Don't try for any fancy finger grooves ... just a simple "fat in the middle" puukko style is best.

Once done, finish with oils or a wood finish as needed by your material choice.

Unwrap the taped blade and make a sheath for it.

Viel Glück!
 
Thank you Stacy, that is some good advice.

I have just ordered all the bits and pieces I should need (including 2 hand forged blades with long narrow tangs - one is Mäkinen 95mm and one Kuikka 80mm). I will be ordering some files soon. I still need to get some nice birch bark as I also want to try that kind of handle - I am in the process of locating some good quality one in Germany or EU. If anyone knows of good source I would be grateful.

I am considering to get the Knifemaking book from Holly Boswell and maybe also book about making leather sheats from Thomas Löfgren (German edition). They both seem to be higly regarded around here.

Once I have all the items at home I will start a new thread posting the status and asking questions on the way.

I am really looking forward to this project :)


EDIT: Just sourced some good looking (should be souitbale for handles) birch bark. 1kg should get me started :)

EDIT 2: Just ordered the Knifemaking book from H. Boswell :)
 
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Since I have started ordering the components I have also started to think about the process and questions pop up, here are the first few
1) Currently I only have hand-held drill which does not have a provision to be mounted to a stand that would allow to drill in a controlled manner. Is there some trick that would allow me to get a decent-enough alignment?

2) Once the handle (let's say it is a simple wooden one with some brass bolsters) is glued together - do you guys just start taking the material off with a rasp, or do you first cut the bulk of the material to be removed with a saw? And if you do use a saw - what kind of saw?

thanks
 
1) I actually prefer using a hand drill to make the hole for a through-tang. First find the center of the block end, and make a small depression there (think of it like using a center-punch to mark metal, I use a pocket knife to bore a small hole in wood). Do this on both ends of the block. Clamp the block into your vise so the hole will be horizontal. Using a long drill bit a little smaller than the thickness of the blade, holding the drill as horizontal as possible, eyeing down the handle block to keep the hole lined up with the handle block, drill a little more than halfway through... then flip the block and drill about halfway from the other end. If your eyeballing skills are good, the two holes should meet. If you will be using a bolster and buttcap, you can now open the hole up with a larger diameter bit. These are the tools I use for fitting a tang:
DSCN0184_zpsd0hvoe10.jpg


2)Once the bolster is fit to the blade, shape it close to the shape you want it, just slightly (1mm tops, especially if you are using all hand tools) oversize. I personally like to also shape the handle close to its finished size before I glue everything together, but this is not necessary, I just feel it makes things easier than trying to do it afterwards... your mileage may vary. You will need a very snug fit between the tang and handle material if you do it this way. If not, a coping saw followed by a rasp would be your best bet.
 
The book, "Knifemaking" by Bo Bergman is the puukko makers bible. It used to be readily available in Swedish and IIRC, in German. English copies are pricy and hard to find.

There are many online tutorials on making a puukko. Here are a few:
http://www.northcoastknives.com/northcoast_knives_tutorials_puukko.htm
https://nordiskaknivar.wordpress.com/tag/puukko-tutorial/


Birchbark is a good material for a person with limited equipment. A sharp knife, some files, and sandpaper is about all you need. A hand drill will work fine for making any needed holes. Cut the bark into rectangles about 30X40mm. As you cut them, drop in a bowl of water. When all are cut, drain and put in a zip-lock bag to keep moist.
To punch the holes in the bark, use a 6mm leather punch, making two adjacent holes to make a slot. You can cut the slots with a sharp tipped knife, too ( a small woodcarving knife works well). As the slots are cut, slide the pieces on a piece of mild steel that is about the shape of the tang ( called a mandrel). The piece should be about 8" long. Cut two pieces of wood to fit on the ends as if they were a bolster and end block. They are for clamping, so there is no need for them to be a precise fit. Put one block on, slide on the bark, put the other on the end when done. As the stack gets to about 25mm longer than the desired Compress in a vise or with woodworking clamps to squeeze tightly together. Let dry a day or two. Take the pieces off the mandrel and set on an old towel or news paper. The next step will be messy, so do it outside or over paper. Put some wood glue ( I use Tightbond 2) in a bowl. Wax the mandrel well with beeswax so it won't stick to the bark pieces as they get glued up. Put one wood block on the mandrel, then a piece of waxed paper, and then start gluing up the handle. Dip a bark piece in the glue, squeegee off the excess with your fingers, slide it in the mandrel, repeat until all are on. Slip on another piece of waxed paper and then the end block. Wash your hands and then clamp in the vise or clamps to tighten up the stack. Wipe off the excess glue squeeze out and tighten again. When the stack is tight, let cure for a week. Take apart and clean out the hole if needed. If the mandrel is stuck, just set the stack on a slit somewhere and hit the end of the mandrel with a hammer ... it will drive out easily. Remove the wooden ends and you now have your birchbark handle block. You could do all this on the actual blade tang, but it is a lot easier to do on a mandrel first.

Now you can carve the handle to a basic shape with a sharp carving knife. A belt sander is a much faster way to get the basic shape if one is available to you. Talk to someone who does woodworking about them helping with that. BTW, the mandrel is a good way of holding on to the handle block while shaping it, so don't toss it away.

Once the corners are cut/ground off, slowly shape the handle to the desires profile. A basic "fatter in the middle" oval shape is best for a puukko. Leave some room for the final shaping once the knife is assembled.
After the basic shape is done, it is time to assemble the handle on the knife. The blade should be taped up to protect it from glue and scratches ... and to keep you from getting cut.. Shape the front bolster piece fully and sand the front end smooth. You can't really work the front easily once it is on the knife. The end piece only needs the basic shape and a snug fitting slot to the tang. When the front Bolster/guard and end cap/block is ready, slide the bolster on the knife with a little epoxy in the joint, slide the handle on with epoxy in the hole, slide on the end block and clamp the knife tight while the resin dries. Use 1 hour or longer cure epoxy. Do NOT use 5 minute type, or you will have problems. Once the knife is in the clamp. wipe off any excess resin on the blade, and then clean off with denatured alcohol ( the best solvent for epoxy). Let cure overnight and take out of the clamps. Cut off the tang about 2-3mm past the end block and round over with a ball peen hammer. File to shape as needed and you are ready to do the final handle shaping. Use files and sandpaper to get the right shape and feel. Once it is right, sand to at least 400 grit. The handle can be oiled with linseed oil, treated with a wood finish like polyurethane or Minwax. or waxed with beeswax and hand buffed. The beeswax is a good and easily renewed finish. Just paint with melted beeswax, let cool a bit, and rub hard with an old tee-shirt.

A simple puukko sheath is just a leather "wrap" style sheath ( sometimes called a pocket sheath) that comes about half way to two thirds up the handle. The leather sheath can be oiled with Neatsfoot oil and then or waxed just like the handle.

Attached is a photo of a birchbark puukko I did in December. The front and rear blocks are reindeer horn.
 

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Thanks Stacy. That is some great information - answers quite a few of questions I had in mind. I have just got material to build a clamp for the handle gluing.

One quick question about the glue - is there a relevant difference (for the purpose intended) between titebond 2 and 3? I know that the 3 is used for cutting boards as it is food-safe. And since both cost about the same I am wondering whether I should get the 3.

EDIT: That is a very cool knife - I would call it camp puukko :)
 
Tightbond 3 is waterproof and Tightbond 2 is water resistant. There is little difference, otherwise. On a knife handle either will work. On a picnic table in the back yard, use 3.
 
Wieland Verlag have good German books on knife and sheath making (most translated in to English as well)
If you like knives you'll like the magazine as well.
A simple and not to expensive drill press from Hellweg will go a long way if you decide to do more knife making
HT can be outsourced for 8 or 9 euro's per blade if you want to make your own
 
Thanks for the information - there are indeed some interesting books available.

I also checked drill-press options - surprisingly it is possible to get a decent one for about 200€, but given the fact that I have about 2 square meters of space in the basement, I do not want to start buying bulky stuff. In general I will be getting tools on the way as I will need them. And I do not want to overstretch patience of my better half - remember that my workshop is our kitchen :)

You are reading my thoughts - I would love to try making blades and already found 2 or 3 places in Germany that would do the HT, but first things first. It will already be a great step if I manage to make a knife with ready-made handle. If I manage that and then make a few more - and enjoy it, than I might try that. All I did until now is reading up stuff online and spent money on tools and material while sitting on a sofa and sipping tea, so let's not get ahead of myself :)

BTW - those sticky threads are awesome!
 
You can get a drill press for app. 100euro. Invest in good drill bits. (Co drill bits)
UHU endfest epoxy (24hrs) is used a lot for knife making in Germany. (I use it as well) You can find it localy or otherwise on ebay.de
Remember that epoxy hardens best when warm and will not harden cold.
 
I already ordered the Knifemaking book from Bergman, it will be however a week or two until it arrives (from US to DE).

I have used UHU epoxy (both fast and slow curing) a couple of times and made very good experience with it (most notably when making a magnetic wooden holder for kitchen knives).

I am now going through the tons of youtube videos and try to figure out what is it that I really need and what not. I have also realised that one option to get access to some machinery could be some local public organisation of some sorts, but did not find much in that regards yet.

Hengelo, since you are making knives AND located in Germany, I would appreciate any input concerning tools. My only guide are reviews on Amazon at the moment (most tools/marks discussed on this forum are not available in Germany). Thank you :)
 
Before even scraping the skin off the first piece of birch bark, or cutting the piece of that 5mm thick brass plate for a first bolster I somehow find myself with 750x40x3.5 mm 52100 plate (2 smaller ones from 80CrV on the way) and ordering parts to build this:

What is happening to me? :o :D

https://www.youtube.com/watch?v=r9iNDRwwBQQ
 
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