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Bowie WIP - Knife now complete

I started working on the handle today. I took my handle template, and glued it to my handle block. I am using a block of stabilized Hawaiian mango.



I lined up the area for the tang slot, and drilled three holes to get it started. I started with a short bit on the drill press, as my longer bit would not fit with the handle block standing up. I later drilled the rest of the way with a hand drill.



Then it's time to use the broach and clean out the tang slot. Beautiful isnt't it?


Once the tang fits into the slot, I cut the block to a rough shape using a coping saw.


I cleaned up the edges on the sander to get it close, and rough shaped the guard. All of the finish grinding will be done once the handle is epoxied on. It's hard to see, but I also added a leather spacer between the copper and the handle.




Now I'm just waiting for some copper pin stock before I drill the pin hole, and epoxy on the handle.
 
Looking good, but I would NOT leave that leather spacer in there. The leather will want to move on you, and being mated next to the copper, it will almost definitely turn your copper all kinds of funky colors in a short time.
 
Good call on leaving the leather out.
Looking forward to seeing your handle take shape.
Darcy:)
 
Thanks gents. This has been a time consuming project but I'm really enjoying it. I think I'll tackle a smaller hidden tang next.
 
OK I finally got some 1/8 copper pin stock for this knife, so I can continue.

I drilled and reamed the pin hole through the handle. Then I marked the tang with sharpie. The tang was placed into the handle, then I marked where the pin hole comes through. Then I drilled the tang hole oversized (3/16). This allows a bit of play and let's the handle sit tight against the guard. The rest of the hole will be filled with epoxy, so it won't make a structural difference.





I mixed up some G Flex epoxy then heated it up slightly with a heat gun. This makes the epoxy thinner and easier to pour into the tang hole. Here it is all glued up. I'll need to make a better gluing jig for future projects. But this works for now.
 
This a great thread with lots of info. Really like the hamond. Can't wait to see the finished handle and guard!
 
Mr Alexander, I am a little late checking out your WIP. My loss not looking sooner! Great looking work, and a great thread. Thanks for posting. I, too, like your "hamond"!!!!!
 
Please, call me Shane.

Thanks for the comments guys. I'm also looking forward to finishing this up.
 
We need a "popcorn" smiley:D looking forward to the handle shaping.
Darcy
 
Darcy i sure could have used some popcorn reading this thread. i have ambitions to make my own knives someday and this thread is so awesome Shane. the knife is coming together wonderfully and looks beautiful throughout the process. i cant believe i missed this thread! keep it up Shane and you will inspire many other people like myself
 
Here I have ground the handle down to the shape of my template. I then sanded the template off and got into handle shaping.


The next few pictures are the rough shape of the handle from the grinder. I need to do a little more grinder work, then it's on to files and sandpaper.






So far the balance point is right at the rear of the guard. It should balance pretty much on the guard when I'm done shaping the handle.
 
Man you got me checkin this thing like three times a day seein if you have progressed with it any more. Lookin good!
 
Here are a couple of shots of the handle after a rough shaping with files. This gets me a little closer to the final shape I am looking for.





Here I have started hand sanding just the rear portion of the handle at 80 grit. The shape is almost where I want it now.
It feels great in the hand already.



 
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