Epoxies and Scales

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ZERT8208

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Apr 8, 2015
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I made a set of walnut scales with copper and G10 spacers and liners. Im having a lot of trouble with the copper and G10 spacers and liners coming apart from one another. They seem to be sticking well and then once I start sanding and profiling the handle, they just come apart. I am currently using Gorilla glue 2 part epoxy. I have made sure to scuff the surfaces of all parts heavily and clean them well. Any tips for multi piece scales?
 
If you are getting the surfaces clean I would guess that you are over-clamping. To tight in the clamps will squeeze out all the epoxy. Too loose and you have ugly gaps. Its kind of a fine line.

Another thing is heat. If you generate too much heat while sanding the epoxy will release. Go slow and use new abrasives.

Otherwise I would try a different epoxy. I recommend Acraglas gel. It has really long working times so you can take your time with the clamp-ups.
 
It does seem to happen when sanding or trimming them on the band saw. So maybe it is the heat. The copper gets a lot hotter than most other materials I have worked with. Im paranoid that the handle is going to come apart now down the road.
 
West system G Flex epoxy is also another good epoxy. You can find it at some marine supply stores.
 
I learned the hard way a few times that over clamping does indeed squeeze all the epoxy out. Simple spring clamps are the way to go. G flex epoxy is the best stuff out there in my opinion.
 
You could also honeycomb the tang side of the scales, just deep enough to hit the Walnut. If spread properly, the epoxy will flow up into the drilled holes and give you a more secure bond with the multiple layers, and a better bond to the blade due to the depth of the epoxy. I believe Brownell's recommends at least .007" or .008" thickness of epoxy for a great bond, other manufactures could be different though.
 
Thanks for the input guys. That may be the issue im having. I did clamp the hell out of them.
 
If you use mechanical fasteners, this shouldn't be a problem.
Cutting your laminate with a bandsaw creates several problems: copper cuts rather "gummy." It also transfers heat well- so you have friction because of the gummy cutting consistency. This creates heat- which breaks down the epoxy. The saw also pulls the materials apart while it's cutting.
 
West Systems advocates wet sanding on many metals- wetting with epoxy just prior to gluing, and sanding. That gives a fresh surface that hasn't been exposed to much oxygen, and so hasn't built up any oxide layer.
 
I cut the scales roughly to size and drill my holes. Then I glue my liner(s) to my scales and clamp to something flat. I use my quench plates. Leave the liner(s) big. After it sets up drill the holes all the way through and counterbore the holes since I use corby bolts. Bolt the scales on the knife and grind the excess away. Pull it off and flatten the backside.
 
ZERT8208 said:
Bill, do you have any suggestions on cutting the laminate scales that would work better?
Click to expand...

I don't use G10 or carbon fiber, but- using a very fine toothed blade will help eliminate some of the problem. Maybe a squirt of WD 40 would help, too.
 
Diamond grit bandsaw blade is what we used for cutting composite slabs.

You need to be really carfule with heat generation, your not only loosing your epoxy but probably damaging the resin on the scales themselves.
 
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