Xander,
To be sure, having a kit did allow me to figure out what was important. In some ways, having the kit can mess you up too. When I made the blade to replace the one in the kit, I didn't understand how important it was to make absolutely sure both stop pins were in a perfectly straight line in the center of the blade. What I did with that was simply use the trainer blade as a template and tried to just copy the holes by marking through the original holes to the new blade. That resulted in a blade that didn't line up perfectly when open. Having learned the importance of insuring the proper centering, I was better prepared to do that with this project.
The kit also had one too many holes in the bottom of the handles. They did that to enable the user to move the latch from one side to the other. That seemed pretty pointless to me, so I didn't drill the extra hole. Also, the spacer parts in the kit were a specific shape and size... which works well for the way those holes were drilled in the kit, but since my holes were drilled differently, I needed different spacer pieces.
Something else to consider... the orientation of those pieces (and the associated holes) at the bottom of the handle is important. Get it wrong and the blade will contact them as you're closing the handles around it. Get it right and it all fits together nicely. You'll want to think about that orientation as you're applying the decorations to the handle, since you'll want them to come together a specific way.
There are several ways you can mess yourself up when making a balisong. I think I did all of them at one point or another. But that's why I did this project... to learn from those mistakes.
If you really like balisongs I'd say just go for it... try your hand at making one. I think I saved a scanned image of the original kit pieces, which (if printed) would provide you with a pattern for the parts and the holes. Where you go from there is up to you.
By the way, if you're wondering about how I joined the handles together... I made rivets out of nails. Basically, I countersunk the holes to match some nails I had on hand. I took a bolt cutter and trimmed the nials down to about the right size, leaving about an eighth of an inch extra. I then sanded the cut end of the nail flat and used the center punch tool to put a dimple in the center of the flattened cut end. I used a carbide drill bit to cut a cone shaped dimple. I then positioned the nails in place, and pounded on the dimpled end with a nail setting punch that had an inwardly domed tip. The result was that the nail mushroomed out to fill the countersunk hole. I then sanded it to the level of the rest of the handle, making it virtually disappear.
Not exactly an elegant solution, but it was cheap. One thing, though... I would not recommend using this approach for the latch piece. I determined that the reason it is having trouble closing is that the nail bent slightly due to the enlarged hole I drilled in the latch to allow it to swing freely. So instead, I'd recommend using some kind of bolt (like a Corby) on any pivot point for a moving part.
- Greg