Ergonomic Walnut Handle for a Bura BAS Villager

[wardenc]

I received my Bura BAS handyman special last week. Just the blade and sturdy hidden tang.

I have made some American Black Walnut scales and am in the process of fitting them to my hand.

This is my first handle on a knife - I normally just do handyman woodwork!!

The basic process is as follows:

(1) Cut 2 blocks of walnut into scales.
(2) Route out the tang shape
(3) Join the two blocks with wood glue & clamp.
(4) Whittle the basic block into a rough, symmetric handle of roughly correct size for my hand.
(5) Wet my hand and grip the handle.
(6) Draw round the wet patch.
(7) Start to carve out the hand shape using a Dremel with carbide carving bits. Not cutting deep.
(8) Use common sense on how deep to go to start with (2mm or so).
(9) Hold, observe, feel. Carve lightly. Repeat. repeat repeat.
(10) Sand out dremmel 'ridges'

I cannot describe exactly how I did step 9, it was very much touchy feely. However I now have the handle so it feels perfect. I am a right hander and the back right hand side is flatter and the left side more rounded and with finger dimples.

Just finishing off and have sanded smooth. Danish oiled, wire-wooled, etc. Normal finishing techniques. 4 hours from start to near finish.

I am in Denmark on business at the moment - but when I return to the UK I will post pictures of the finished result.

 

[Steely_Gunz]

Sounds great Can't wait to see how it turns out:thumbup:

 

[Fiddleback]

Can't wait to see the pics!

 

[DrThunder88]

That sounds really nice! BASes are my personal favorite, and I've always liked walnut wood. Looks like a solid plan, and I too am anxious to see the result.

I've had my eyes open for a handyman deal recently for a project I'm envisioning. Just got to keep my eyes open and my dorsal fin up!

 

[wardenc]

Pictures....

 

[wardenc]

Fits like magic!

 

[ilbruche]

GROOVY! :thumbup:

 

[DrThunder88]

It's very melted and smooth, almost like a river rock. I like it! It looks like a very tight seam too. Beautiful work. Do you have any full-length shots of the knife? I'd like to see the profile for the whole shebang.

 

[Ad Astra]

I bet that feels great- looks great, too.


Mike

 

[alexanderkbaker]

Looks good but when your swinging it it seems like it might slip with such a narrow back peice. Typically there wide at the end of the handle for more grip when swung in a chopping motion.

 

[greenwoods]

That's a nice looking handle. Very personal and that walnut has a natural warmth and strength.

Mark

 

[wardenc]

I can see the point about slippage, however, you have to feel it in your hand. It feels very secure and the finger grips are deeper than they look.

It also is not that narrow, particularly in the middle as my hand is the size you would expect from a 6' 6" fella.

Once I glue it up i'll let u know how it chops.

 

[wardenc]

Just a quick update on my handle project. The contoured handle worked reasonably well but as somebody pointed out it can slip slightly. I have solved the problem by going back to the wisdom used to make sword handles of old - Ray Skin. Amazing material - tough as hell and stretches beautifully when wet. Grip is like 'sandpaper' but comfortable - I can see why this fish leather was used - it is supposed to be the toughest leather out there & was used in Samurai armour!!!.

Photo below.

The edge of the skin is naturally tapered and the cut side of the leather tapered with a dremel (it is TOUGH) - held in place with tiny panel pins (later removed) to start and damp skin stretched over handle with waterproof pvc - dries very tight and taper is totally smooth!!! 2mm braided cord at each end soaked in semi-matt resin. Pic of tapered side - I upped the contrast a bit to try and show that it blends in dead flat & seamless - not sure if the pic was a success!!!. I went for a diagonal join on one side - depends on how you cut the skin (using a cleaver & hammer and refined the edges with a dremel and fine cutting blade when on the handle - u cannot just cut this stuff with shears!) but it could be done in a straight line on the underside of the handle:

Works a treat!!!!!!

 

[greenwoods]

I Love It!
I bet it feels great. I've weilded a small Katana with Ray and it was just great. You've inspired me to use it on a knife handle soon.
Thanks for the update

Mark

 

[ferguson]

Now that is cool. :thumbup:

Steve

 

[Jaymo]

Where can I buy rayskin? I'm sold on it.

 

[wardenc]

Hi - I got mine from eBay. It is the traditional leather used for sword grips - but now widely used for other things like wallets. Try searching on the web for a supplier. I just used 'Rayskin leather' on google and it threw up a lot.