Can G-10 be worked w/ only hand tools?

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me2

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Oct 11, 2003
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I have a bug to replace the wooden handles on a kit knife I made with G-10. I'm planning on hand wet sanding the bevels and faces. Is this a reasonable way to go? Can I cut it with a hand saw? How about files? What would be a good grit to finish?
 
Yes you can cut it with a handsaw but it is not to quick.

It hand sands fairly well. I've beveled the edges on the G10 on almost every knife I have made by hand.
 
Yes you can. I find it harder to saw but it sands and files really easily. Use a saw with a blade meant for cutting metal.
 
If I try to pein the pins or flare hollow tubing, will it split? If not, would it be possible to countersink the pin holes and then file them flush after peining? I did this on some brass and the pins are barely visible, just the way I wanted.
 
G10 is very unlikely to split or crack, just not in the nature of the material.

As for grit, it depends on what you want as the end result. I have sanded it down to 800 then taken a buffer to it for a shiny and polished look. It's almost impossible to get it completely texture free without some sort of extra material like a wax or epoxy layer but with buffing you can get it close enough that it's hard to tell. Just going to 400 or 600 gives a nice smooth feel but not slick generally.
 
me2 said:
...would it be possible to countersink the pin holes and then file them flush after peining?
Click to expand...

Yes, that works very well. Cutting G10 by hand is a pain but filing, drilling and sanding it is no big deal.
 
I replaced the scales on one of my Gerber folders with G-10. I used a coping saw with fine-tooth blades (20tpi, I think) to cut it, and sandpaper to shape it. Started at 80 and finished at 220 grit. 220 gives a smooth matte finish with a good secure grip.

You could buy everything I used - saw frame, blades, and sandpaper - for about $15 at Lowe's or Home Depot.

Since nobody else has mentioned it, be VERY sure to use a good respirator. Even with hand tools, G-10 raises a lot of dust, and it's way hard on your lungs.
 
I have most of the hand tools already, and the dust issues is the reason for wet sanding. The trick will be to get some coarse wet/dry sandpaper.
 
You can use a file for your rough-shaping, it will be faster than most any sandpaper. 3M wet-dry is available down to 220-grit which is pretty agressive.

You should still wear at least a dust-mask and ventilation, even wet-sanding. You can't be too careful with this stuff.

Dig out an old box fan somewhere and tape a furnace filter to the back to protect the motor. Set it up to suck any stray dust away from you, into the fiter. It's not a pro set-up but it does help.
 
From the sound of things, the G-10 is not worth the hassle to me. How about linen or paper Micarta? Same plan, hand files, wet sanding, maybe a rasp if it will work. It worked beautifully on my wood handle. I was planning on a 400ish grit finish.
 
Paper or linen micarta will certainly make a good handle, and is much less expensive than G10.
 
No matter what material you use, protect your lungs! Even wood dust will cause you problems over time.
 
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