Fitting hardwood inserts

Eric T. Maier

Eric T. Maier

Joined
Apr 29, 2000
Messages
573
Hello all,

I need some advise on fitting inserts. I can not seem to get the ends to match up perfectly with the metal of the knife handle. Is there a guide or any tips and tricks for getting the perfect joints that I see al the time? Let me know if I'm explaining myself alright.

Thanks for any help,

Mer
 
my sugestion is to think flat, the metal will need
to be flat, then the wood needs to be flat. for
spacer type incerts the eseay way is to make them
paralell. Iuse a flat disc sander for this Gib
 
One way to do it is, make a dam around the handle, with tape. Coat the handle with release agent, then pour casting resin in. After it is dry, you will have a perfectly fitting pattern.
You did not mention if the bolsters(if it has any), are dovetailed or not. But in either case with the pattern, you should be able to make your handle material fit.
 
Mer, the only way I've found for perfect inserts is to file a liiiittle bit at a time. These other guys are much more experienced and might know a better way though.

Also, on the Sidewinder balisong that I changed the inserts in, I filled any extra space with epoxy. I saved some of the sanding dust from the wood and mixed it with the epoxy to make it roughly the same color. Worked OK. 'Course I was using Bloodwood so it only had to be red.
 
I think flat is the answer as Gib said. I use my grinder to get it flattish, then use coarse sandpaper glued with rubber cement to a piece of glass. That gives me one flat surface to work with. I can then position the handle on and use a fine tooth saw to cut between the wood (Or bone, etc)and the spacer. This gives me an acceptable fit. I will fit and sand enough times to get the fit I want. This is an important part of the knife and one that makes a knifemaker show his skill.

After I fit them and glue, I grind both spacers and handle at the same time.
 
I had the same problem trying to use my grinder. I now get as close as I can and then use files or a flat surface with sandpaper to finish up the fit. Throw in lots of trial fitting to boot. Putting some liner material in between surfaces will also increase the fudge factor.
 
Hey Mer,
I assume this is a Balisong , no ? If so, what are the bolster areas looking like ? are the tops angled or are they straight across ? Did you mill the handles ? are they ovular like say the 49 spl ? In any of those cases as long as you can get the length and width exact to the inside if the piece you're fitting them into your fine. Just have some oversizing in the depth so that you can sand it off then it will look flush. I'm real curious, are the inside ends of the area/ handle to be fitted with inserts rounded ? I'm sure you'll get it right. Give us some more specific info. Good luck, take care.....RDT
 
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