BK24 Scales WIP ** Pic Heavy **

[tjswarbrick]

You may have seen my Becker 24/7 thread. I'm currently working on scales for the 24. If successful, I'll move on to similar ones for the 7.
I don't have much of a workshop - just hand-held tools, along with a Dremel workstation:

In addition to that, it's hand drill, Worksharp portable belt sander, hand jig saw, hack saw, triangle, round, 1/2-round and flat files, sandpaper, and occasional Becker.
I did mount the jig saw, upside down, to a board which was affixed to a pair of sawhorses to simulate a table saw. I can't say I recommend it, but once I set it for complex work in sheetmetal, it made cleaner cuts faster than my hacksaw.

 

[tjswarbrick]

I worked up some mycarta from brown and natural burlap with Bondo fiberglass epoxy resin.

They were kinda thin, so I bonded 'em to .030 white G10 and 3/16 linen micarta with CA glue.

 

[tjswarbrick]

During a moment of absentmindedness, the 24 bit me.

Now I know it's mine. I also figured out how to make a simple cover with liner material and duct tape. Duh!

Things have been progressing nicely, but I still have a bit of work to do:

I'm hoping to improve my lightbox, and camera skills, simultaneously with this project so things won't look quite so bad when I'm done.

 

[SideTracked]

Cool project. You're making it work with what you have available and that is certainly commendable.

 

[tjswarbrick]

Thanks,

I didn't realize how off-center my counterbores are. Easier to see in photo than real life! The front one takes the hardware just fine. The rear may need slightly reworked. Haven't tried the middle one yet. Also note, a Dremel Workstation is not a Drill Press. Way too much plastic in critical places.
I could feel it wobbling as I drilled. They work just fine, but I would never accept such out-of-round holes in something I bought from someone else. However, for hand made by me, when they'll be covered up by hardware, I see absolutely nothing wrong with using 'em.

 

[Tommythewho]

Thanks,

Easier to see in photo than real life!

You hit that nail on the head, it is amazing what you will see in a picture that you completely overlook while doing a visual inspection.

 

[tjswarbrick]

How would you know, Tommy? All your work looks absolutely perfect, to me.
In fact, knowing your stunning wood scales are available if I honk this all up has given me courage to proceed.

They're coming along nicely, though, I think. As long as I can stuff 'em into the sheath I have coming, I'd call the "off" side 90% complete.

Here's a shot of my inspiration: handmade Mycarta on the 16, and Andy's gorgeous, and sublimely ergonomic, 3-tone handle work on my KE Bushie.

 

[CamH_16]

Looks good, nothing wrong with using hand tools over a belt sander...It may be slower but it's definitely more precise.

 

[tjswarbrick]

Thanks Cam.
I've seen your scales, so that means a lot.
I still want the belt sander...

 

[CamH_16]

Thanks Cam.
I've seen your scales, so that means a lot.
I still want the belt sander...

Yeah, the belt sander is a pretty important tool and I still use it for rough shaping to save time but I've found for final shaping files and sandpaper are king. Why don't you pick up one of the Harbor Freight ones for like $30?

 

[tjswarbrick]

Yeah, the belt sander is a pretty important tool and I still use it for rough shaping to save time but I've found for final shaping files and sandpaper are king. Why don't you pick up one of the Harbor Freight ones for like $30?

Because, first, I need a table saw. Then, if I get the HF, I'm going to want the Porter Cable (or Grizzly.) And if I get the Belt Sander, I'm going to need the Drill Press, and probably a spindle sander. And a new router, since my old one doesn't turn off anymore.
And I only have a (rather full) 1 car garage. And if I get all this stuff it'll be years before I recoup the costs through little home projects.
(Sounds a lot like a knife addiction, actually.)
Still, I'm thinking, if/when we get a bigger house with a bigger garage...

 

[Eero]

Those are coming along nice. I like the texture in slabs. Well done.

 

[tjswarbrick]

Got the presentation side to more-or-less match the other, and cleaned 'em up with mineral spirits.

 

[tjswarbrick]

Matched 'em up, cleaned /em off, oiled 'em with Feibing's neatsfoot to condition the burlap and make the linen "pop".
Installed with fresh hardware.

If I push it in with a bit of force, I can get it into the stock sheath. Hopefully that means it'll fit the leather one on it's way with just a little work.

I was paying so much attention to matching them up that I forgot to routinely check the thickness. They're actually a but thinner than I would have liked. They filled my XL hands more naturally in the 4th pic of Post#3. I have some .070 Kydex I could make liners out of, but I'm not sure how that would work out with the inset portions.

They're actually 3/8 (.370", really) thick at the widest section, including the inset. I read that either the BK14 or Izula scales are .25" thick, but I'm not sure if that includes the inserted portion, making the knife OAL max width .5" - or if that's in addition to the insert portion/handle spine thickness.
Mine gives a max of .730" thick at the palm swell. Certainly bigger than the .165 spine, but not as hand-filling as I had hoped for. Still gives a nice 3-finger grip.

Also, the hardware is a little proud of the scales - probably an effect of over-machining. I hesitate to sink them further, as the counter-bores already extend down to the G10 liners. Should I risk it? Grind the fasteners flush with the handle? Just leave it?

I noted a bit of a gap between scales and spine. I've got some interference in the lanyard-hole portion of the inserts. Should be able to take care of that in the morning. Should I do something with the hardware at the same time?

 

[Tdhurl1103]

Nice job. I think you did good! I wish I had the patience for something like this, or the time, or the motivation, or the money, or th.......er, I'll shut up now

 

[tjswarbrick]

Thank you.
It's mostly time, I'm afraid. Unless you need 'em oversize, like me, or just want your own custom jobbies - buy the Izula scales and file 'em to fit.
I wanted custom, though.

So, I went back and re-ground the insert on one side. I decided to grind down the hardware a bit, too. Just holding it, with all 6 heads proud of the scales, was annoying rather than fun.
Also decided to stick with the thickness as-is. The original plan was 1/8" larger than factory - like adding .060 liners to each side. That would yield ~ .62". I'm over that by nearly 100% - so I'm calling it good.
Since I will likely do moderate food prep with this guy, I washed everything down with dish soap, dried well, and applied and wiped off a mixture of 1/2 roasted walnut and 1/2 USP mineral oils.
Also changed up the setting again, just a bit:

With the middle brother:

How it looks in its natural habitat - outside:

I'm outta here. Gotta go cut something.

 

[Psyop]

That looks great!

 

[tjswarbrick]

Thanks Chris.
Looking forward to a way to carry it...

 

[Hunter Sharp]

Those came out pretty darn good!

 

[tjswarbrick]

Pretty rough, but I've started to BK7 scales.
Haven't stripped it yet, because I'm sure it'll need it once I'm done with these.