Epoxy handle filler on partial tang?

[oic0]

One of my coworkers got married and rather than buy him a gift I figured I'd make him a kitchen knife. He loves to cook. I only had a little bit of wide steel left so the planned handle was going to be on the shortish side. I've already glued the scales on and was going to have the knife have a short handle but as I'm grinding away I think it would balance and handle better if the handle were longer. Would it be a bad idea to leave some butt on there, tape it up on the sides, fill with dyed epoxy, then grind to shape? There is plenty of scale overhang to make it happen.

 

[tinkerer]

When I need filler, I use Devcon Steel Filled Epoxy, 10110. Pack it in and store in with the hole up so it settles towards the tang. Hardens to stone and is machinable. I also use it in all stick tangs so it fills all the inside of the handle.

Larry
Tinkerer

 

[Stacy E. Apelt - Bladesmith]

Epoxy isn't really going to work or look good for filling the gap.

Your best options are to leave it as is or take the scales off and replace them with longer scales in a 3/4 tang assembly. To do that, grind the tang end square. Make a piece of handle material the exact thickness of the tang. The material can be of the same type as the scales, or contrasting ( I like contrast). Place the scales on the tang as usual, with the thin piece in the gap beyond the tang. Make sure it is snug against the tang end.

If you want to try and make the filler piece to fit the tang end and slip it in the gap between the extra scale length you have now, it is worth a try. You will have to carefully clean out any dried epoxy and then carefully shape the inset piece to fit the tang end. If you get it to where it dry fits good, just epoxy up the gap well and slip in the filler piece.

Depending on how much length you add, you may need to add a last pin/rivet to make the handle pins look balanced. I would wait to do that until after the handle is rough shaped.