Dex's Saber 16 Modification WIP : Progress Update

[Dexwithers]

Ok, so I haven't really done any mods on this one in a while. Have just been using it as is and trying to decide what to do next. I was going to use wood for scales but after I saw how much some wood scales shrink and expand with the weather changes I decided to go a different route. I ordered some linen micarta that came in last week and finally had a chance today to start work on them.

I took some pics to show the process I used. I don't have a lot of fancy equipment but I improvise with what I do have.

Please excuse the mess. My workshop is a complete disaster and I have about 10 different projects going on in there.

Here is the blank slab of Black linen.

Cutting them out on the ole bandsaw.

Oh yea, lets get these fitted!

Time to Drill.

Not sure yet what I'm going to do to the back of the handle yet so I figured I better make the lanyard hole now just incase I decide to leave some scale back there.

Finished up with a file.

Time for the other side.

Sure wish I had real drum sander and a belt sander. I don't so I used my drill press. Actually works pretty good.
I needed to get the front shaped the way I wanted because there is no real easy way to do it after the scales are installed.

Not bad. When I got close to the original scales.I put some tape to give me a buffer so I would have a little room to finish them smoother.

Let me tell ya, everyone should have a worksharp. I really don't use it to sharpen my knifes, but I do use it on everything else. Put that sucker in the vice and I'm good to go.

After finish sanding the front of the scales.

Got them perfect.

Time to finish the rest of the shaping. I decided to get it done now before I pin and epoxy them on to give me some time to decide if I want liners or not. I am leaning towards no just to keep it simple and elegant.

Got it done and man that stuff is messy. And yes I wore a respirator mask. I think you can die from breathing that stuff.

That's all I have done so far. Maybe pin and epoxy on tomorrow then start shaping the contours.

I think I really want to keep this knife simple and not do any real crazy mods since it is such a rare blade. I think the new handles will do her well.

 

[The Warrior]

Looking good man. :thumbup:

 

[Dexwithers]

Thanks Warrior! I can't wait to see her all finished.

 

[NathanJ]

Looking good!

 

[hawaiianhawk]

Looks great, Dex! The two-tone finish is pretty damn hot, and I think those black micarta scales are just gonna set the whole thing off.

Also nice use of the Worksharp. I want one.

 

[hawkhead]

Looking good, Dex. Can't wait to see your 16 completed.

 

[Cryptyc]

Looking darn good so far. I see you are going the permanent route with the pin and epoxy. Very cool.

 

[TBL]

Looks good Dex! can't wait to see her completed!

 

[granitestateofmind]

That looks great, Dex. So, what's wrong with using the drill press as a drum sander? That's how I use mine a lot. I have a 4x36 belt/disc sander, but the roller diameter is too large to do some of the contouring and shaping of Becker scales. Plus, with a drill press mounted drum you can set the table square to the drum....can't do that with a belt sander! Now, a dedicated oscillating spindle sander? That'd be nice.
And that WorkSharp is handy as all get out, ain't it? There's your belt sander right there!
So...you're going to pin and epoxy scales to your rare knife blade? Why not bolts? Maybe some threaded inserts epoxied into the underside of one scale so you don't have to make hex cutouts?

 

[Dexwithers]

Thanks Guys!!! I'm really excited about this one. As many of you know, the BK16 is my favorite knife in this size range. And the saber is well, so much sweeter!

That looks great, Dex. So, what's wrong with using the drill press as a drum sander? That's how I use mine a lot. I have a 4x36 belt/disc sander, but the roller diameter is too large to do some of the contouring and shaping of Becker scales. Plus, with a drill press mounted drum you can set the table square to the drum....can't do that with a belt sander! Now, a dedicated oscillating spindle sander? That'd be nice.
And that WorkSharp is handy as all get out, ain't it? There's your belt sander right there!
So...you're going to pin and epoxy scales to your rare knife blade? Why not bolts? Maybe some threaded inserts epoxied into the underside of one scale so you don't have to make hex cutouts?

HaHa! There is nothing wrong with using the drill press as a drum sander. lol Mater of fact, I used to use my old handheld drill like that, just clamp it in the vise, before I got my drill press. But that being said, I really want an oscillating one since I do a lot of wood working and if you don't keep the workpiece moving up and down on different parts of the drum, you will burn your work or wear out a section on the sander.

The belt sander I will eventually get is the one with the table that you can set square and also has a flat plate behind part of the belt. That is what I grew up using in the machine shop to finish parts. I just haven't found one on CL yet. Been looking for over a year now.

And man I love my worksharp. I use it all the time as a belt sander but rarely ever sharpen my knives with it, prefer to do those by hand. I want that new worksharp too!

Yea, I did consider removable scales, but I think the permeant scales will be really nice. I hate having to take scales off and dry the tang after it gets wet or washed. Also I can get the fit and finish a lot nicer and have the scales perfectly flush and polished to the knife tang. I kinda envision something like Barkriver scales.

 

[Dexwithers]

Oh, and one thing I am really considering is adding the thumb divots to the front of the handle scales. I got a TOPS BOB a while back, and man that thing is comfortable when using the divots.

And no, I don't think I will add a bow drill divot so don't ask. Unless you all think its a great idea, then maybe. haha

 

[granitestateofmind]

....I used to use my old handheld drill like that, just clamp it in the vise, before I got my drill press.

I did the same thing, still do in a pinch....that's funny.

The belt sander I will eventually get is the one with the table that you can set square and also has a flat plate behind part of the belt. That is what I grew up using in the machine shop to finish parts. I just haven't found one on CL yet. Been looking for over a year now.

Depending on your needs, I just bought a 2x42 Craftsman for a little less than $150....

Yea, I did consider removable scales, but I think the permeant scales will be really nice. I hate having to take scales off and dry the tang after it gets wet or washed. Also I can get the fit and finish a lot nicer and have the scales perfectly flush and polished to the knife tang. I kinda envision something like Barkriver scales.

OK, since I've been looking a LOT at a Bravo (that Bravo 3m looks sick) I retract my suggestion. That's gonna be the BOMB!

Oh, and one thing I am really considering is adding the thumb divots to the front of the handle scales. I got a TOPS BOB a while back, and man that thing is comfortable when using the divots.
And no, I don't think I will add a bow drill divot so don't ask. Unless you all think its a great idea, then maybe. haha

Man. That TOPS BOB kinda killed mosta my enthusiasm for finding a Saber 16 (I have an FFG)....and I vote "no" on the divot; you can always add one later if you feel the burning need to have one .

 

[The Warrior]

you can always add one later if you feel the burning need to have one .

Stop, you're killin' me Smalls.

 

[CamH_16]

Great job Dex :thumbup:, can't wait to see the final product.

 

[spydercobenchmadekai]

Looks great! I can't wait to see it finished.

 

[Eero]

Thanks for the detailed pictures. It's great for me to see exactly how this is done. Excited to see where this project ends up. Nice work so far

 

[mrn8]

Looks good Dex! I'm also liking the step-by-step pics. I know how I've done handles, but it's also not the only way to do it.

 

[Galeocerdoshark]

That's already looking really good. I'm curious to the end result!

 

[Dexwithers]

Thanks again guys.

I didn't get anymore done yesterday since it went from almost 80 degrees on saturday to the low 30's yesterday. Crazy stuff. Didn't want to set epoxy in the cold.

And yes there are tons of ways to go about making handle scales. I guess we all have to draw from our experiences and what we've learned. Also have to adapt to what tools we have and what skills we are comfortable with.

HaHa........ but if any of you know an easier way, please tell me. haha

 

[CamH_16]

Thanks again guys.

I didn't get anymore done yesterday since it went from almost 80 degrees on saturday to the low 30's yesterday. Crazy stuff. Didn't want to set epoxy in the cold.

And yes there are tons of ways to go about making handle scales. I guess we all have to draw from our experiences and what we've learned. Also have to adapt to what tools we have and what skills we are comfortable with.

HaHa........ but if any of you know an easier way, please tell me. haha

Glue on one side, drill the holes, glue the other scale on and drill that one too and then put the pins in, when its permanently fixed it makes drilling much easier and there's no chance of misaligning the holes.