Alpha Project

jb4570

jb4570

Gold Member
Joined
Aug 26, 2005
Messages
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Happy Friday Night,

Hi all...it's my Saturday night...even though it is Friday night for most. Well I have a few Alpha folders that were Xmas gifts from years past:D. However, they have the black rubber grips....and well...they are not pimped enough for me:o. So I started looking for someone to make me some dressed up scale's:thumbup:. But, for the price I was quoted to do them I could by a whole new knife:confused::eek:(Thats a knife with custom type scales) . So...I said to myself....JB...just do it your self you lazy old fool:D:cool:.

I found some cool looking exotic Bocote wood and started my project. I have the scales ruff cut so far. I'll post more pic's as this project moves forward and time permits. If it works out....I'll do more in stag, Elkadon, and some more fancy wood....got to find some Ironwood with deep grain:D.

Here are the ruff cut scales




jb4570
 
:cool:...Looks like you have a real good start on those scales jb...They look great and the "match up" of the pairs is pretty darn good too...:thumbup:
 
Very nice looking!

So when you gonna start selling them aftermarket? :D
 
Ok these are just about done.




Here are the ruff cut scales




Used a Table Saw to rip the wood from 3/8" to 3/16" (15 min work). Next use a Scroll Saw to ruff cut the handle shape (10-15 min per handle). Next used a Belt Sander to remove some of the wood to help shape handles (5 min per handle). Next hand shaped with Wood Files (15-20 min per handle). Sanded handles to final shape with 150, 320, and 400 grit sandpaper by hand ( 20-30 min per handle). Drilled 9/32" hole through handle for screw and 17/64" counter bore for screw heads (5 min per handle). Sealed wood with Tru-Oil and Stock Sheen from Birchwood Casey (30 min per handle).

Lessons learned:

As always using a Table Saw to rip wood is a chore...especially when the scale starts are short to start with...I still have 8 fingers and 2 thumbs :).

Next the Scroll Saw work was fine no issues to comment on. But, I could have done the same ruff cutting with my Jig Saw and it would have cut some time off the job...next time.

The Belt/disc Sander worked like a charm. I'm glad I got this to reduce the hand file work and save time ruff shaping the handles. I used an 80 grit belt next time I would use a finer grit belt to reduce the hand sanding a bit...a less ruff sanded finish to start with. Hand sanding a shaping tires the old hands a bit ;).

Ok I had a tuff time deciding what drill bits would be best. I wanted to find a counter bore bit that would fit my needs....no luck. I now have a few extra bits that I did not need...at least not for this project. I did guess that thru and thru hole was 9/32" that was correct. However, I incorrectly guessed that the counter bore hole was 1/4"...to small. I correctly determined that 17/64" counter bore would be the ticket.

However, the hardware store did not have that size...&*$##$*....so I setled for a 5/16" counter bore. It was to big for my liking...But, I had alread used it on the first set of scales...Oh well 1st unsatisfactory lesson learned. Found the correct size 17/64" bit and started to drill the next counter bore holes. 2nd unsatisfactory lesson learned when the bit grabbed a scale out of my hand and put a 17/64" hole all the way thru the scale :(...not a happy moment in time (This will be repaired by using a washer inset in the back side of the scale; this will work fine...but I know it there!!!). This also caused a small chip in the scale face.

Tru-Oil looks good on these scale's. I also used Stock Sheen it give a dull finish. But, I will end up polishing with a wax to get a shiny finish on the scales.
 
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Very nice JB! Thanks for the step by step! So for about 2 hours per handle are you going into full production? :D

That grain on those is very nice! Great wood choice!
 
Great Job JB!!!

You might also consider a redesign on those where the wood fills up more of the frame...

What a fun project! :thumbup::thumbup:
 
:thumbup::thumbup::cool:...WOW..Those couldn't possibly look much better John...Great work...Toss me a few chunk'sa dat wood...It's BEEEEOOOOTIFUL...You did a fantastic job...:D
 
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