Becker handle scales, wood, manufacturing process

FAL'ER

FAL'ER

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Mar 31, 2010
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So, I've been working on these knife handle scales for about two months on and off in my "shop". I've made a million mistakes and learned how to fix most of them. I was hoping this would be a tutorial, My 1st tutorial. I'll have to do it in parts.

This is what I have learned, about hole alignment and the milling of handle scales.

A piece of oak 1'' thick, off of a pallet along with my BK 2 and a pvc pipe blade cover. I will use this jet drill press for the drilling.


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Bits used, 3/8 forstner and a dewalt #10 drill countersink, 3/16 & 5/16 brad points.


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Here's a shot showing how I align the screw holes. Those are 2 extra 3/16 bits poked down into the two previously drilled holes.


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This is the piece with the 3/16 brad point holes drilled out for the handle screws and the lanyard hole drilled with a 5/16 brad point. I actually use the BK 2 blade tang as my template.


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Cutting out the countersinks with dewalt # 10. This is one of the most important steps because it keeps the big hole (screw head) lined up with the little hole (screw thread). It took me awhile to figure this out.


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Cutting the two sets in half with bandsaw.


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Halving the halves, the holes will be perfectly aligned now.


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Trimming off the fat, with this upside down jig saw.


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post 500

Insert pic of me sanding the halves to desired thickness 27/64 on the belt sander.
Micrometer inside bolt hole to get to .125 on the screw head shelf. ( KA Bar uses .103 to .105) I go thicker just to be safe.


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3/8 forstner bit used with the depth stop on the press to get me to .125 ish. I make several practice runs on scrap pieces so I don't screw up the handles.


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You folks feel free to ask any questions you may have. I'm sure some of what i'm doing won't make any sense.


Alright, so right here is how I cut out the Hex for the nut. Basically Just run a screw and nut up snug and trace around it with a ballpoint pen.


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The tool I use to cut the points of the hex. It's a wood carving tool in a " V " configuration. Bad pic, My camera didn't cooperate with me on some of these.
I just cut away the inside on the Ballpoint pen lines until I can get a nut to fit snug, but not too tight and flush with the bottom of the hole. It takes some practice.


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tradewater said:
Outstanding. Looking forward to the rest of it :thumbup:
Click to expand...

Here they are all mounted up. The hard part is over at this point. Now it's a bunch of time with that 1/2 round rasp/file and sandpaper of varying grits, then seal it up and it's pretty much done.


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Starting with the rasp. I generally am just trying to copy the feel of the Becker grivory. At this point it's personal feel but i'm trying to thin it out and give it some ergonomics.


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More file work,


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more file/rasp.


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This is them probably 90% finished. Done filing , did some hand sanding and put a quick coat of deft spray laquer on them just to keep them from getting dirty. I'll sand that off later. I did a bushcrafty thing there, Do you see it?



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Looks real gaudy to me. I'm gonna work the upper guard and lower hand guard area to thin them out and round them off a bit.


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Good job my friend. Have had a hankering to give this a go myself.
 
Awesome Job !!! Great tutorial and pics :thumbup:

thanks for taking the time to post this.. much appreciated !!

love the press !! also I'm not familiar with the 'upside down jig' is this literal?? a mount with a jig saw attached, or really a scroll or even band saw??
 
The saw is a Rockwell ..... can't remember the name. But yes it's a saw that specifically takes jigsaw blades. Kind of a scroll saw, jig saw & table saw sorta deal.

and yes those thumb ramps are the bushcrafty thing I added, never seen a Becker yet with those.
 
I am making a set of oak scales myself for my BK-7 and I would like to change the screws out with the type that ESEE uses. I have looked on Jantz but cant find them. Does anyone know what those allan screws with the conector sleeve are called??
 
hanklet0 said:
I am making a set of oak scales myself for my BK-7 and I would like to change the screws out with the type that ESEE uses. I have looked on Jantz but cant find them. Does anyone know what those allan screws with the conector sleeve are called??
Click to expand...

Corby Bolt, possibly.
 
hanklet0 said:
I am making a set of oak scales myself for my BK-7 and I would like to change the screws out with the type that ESEE uses. I have looked on Jantz but cant find them. Does anyone know what those allan screws with the conector sleeve are called??
Click to expand...
The connector sleeve is called standoffs and the screws are flat head.
 
What type of wood should be avoided for handles? And to be a killjoy, don't answer this with 'Balsa.'
 
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