Fixing or replacing Bakelit handle

[Jens Schuetz]

I got a WW1 sword which has a handle made out of Bakelit. It's broken into 4 pieces with some small chips missing. The handle still holds together due to front and back bolster wrapping around most of the fragments. Thus it looks still ok but can't be used for sure.
I dont like to have blades at home which cant be used, at least in theory.
Now I'm wondering if modern glues might be stronger than the original Bakelit which would allow for an easy fix or if there's a way to copy the rather complex shape via a plaster of Paris mold for example and then pouring some resin (?) into it.
What do you suggest?
Thank you!

(Will upload pics in a few)

 

[AVigil]

You want to get some Bob Smith super glue "Insta cure" or "Maxi Cure" insta cure is very watery so if that is a problem the maxi cure is more gel like.

Be sure to buy some un cure debonder for clean up

 

[Frank Niro]

I believe the CA glues and some epoxys will do the job. Use thin plastic shopping bags to help stop over run . Clear plastic tape works real well Don't expect to correct your problem all at once but figure many times to get it done .I suggest both thin and thick CA glue and some set spray.The set spay I often use to pre set the thick CA. Leave this stuff to dry over night before adding more or shaping. This stuff can smell very bad. Ask if they have oderless .
Frank

 

[AVigil]

Frank,

Have you ever used the "Un Cure"?

Once I used it, I can not work without it

 

[Jens Schuetz]

Thank you Frank and AVigil for your help with this.

Here are the pictures.

It doesn't look half bad,

until the rings come off.

What could save the whole thing might be this rectangular channel going through the whole handle. Its to allow the rat tail tang to go through and be secured by a screw at the end.

Theres quite some space around the tang where some epoxy could be filled in, though thats kind of final and probably means destroying the original handle once I might have to remove it in the future. It would also rob me of the possibility to disassemble the sword for maintenance.

Unless there are some better ideas, I'll probably go the epoxy route on the handle,
make a mold of it just in case
then assemble it again and inject more epoxy into it.
I got some excellent epoxy though its been stored in the garage for 2 years (unopened). Do they deteriorate over time?

Thanks again and still open to new ideas.

 

[AVigil]

Many epoxy degrade over time and espeically in a hot garage.

With epoxy you will need to keep the pieces in perfect alignment for awhile.

With super glue it will set in seconds once you press it in place

 

[Jens Schuetz]

Many epoxy degrade over time and espeically in a hot garage.

With epoxy you will need to keep the pieces in perfect alignment for awhile.

With super glue it will set in seconds once you press it in place

New epoxy it is then. Not really cheap but want to give my best shot. Thank you.

What if in addition to the epoxy I drill 4 small holes into each of the bigger pieces and connect them with pins. That should prevent shear forces from breaking the bond but could it cause the Bakelit to break even more around the pins?

 

[timichango]

Frank,

Have you ever used the "Un Cure"?

Once I used it, I can not work without it

I discovered last year that acetone works well on CA too, for cleanup. I had an accident re-bonding some glass in the viewfinder of an old rangefinder camera I was working on, and acetone saved the day and cleaned up a giant cured smear of the stuff inside the camera.

 

[Pinoy Knife]

ok here is how i believe you can fix that.
#1 buy a rifle bedding kit (about $30)
#2 paint on at least 5 layers of the release agent on the tang of the sword( make sure to put putty in the holes if any) wherever you dont want it permanantly stuck.
#3 mix the resin/hardener add 1 tiny drop of black pigment to the epoxy till the color is close to matching
#4 clamp it up (Assemble it) all pieces where you want them
#5 wait a couple of days for the epoxy to fully cure.
Dis assemble it (since you used release agent you can)
this is a great way to fix something like this or make a hidden tang knife that you can actually take apart without any big problems (if you wanted to).
good luck to you i hope this helps.

 

[Frank Niro]

Sees to me I'm on about my third try but haven't had much success with the debonder, Adam. Maybe time to try again. Thanks.
Frank

 

[Jens Schuetz]

ok here is how i believe you can fix that.
#1 buy a rifle bedding kit (about $30)
#2 paint on at least 5 layers of the release agent on the tang of the sword( make sure to put putty in the holes if any) wherever you dont want it permanantly stuck.
#3 mix the resin/hardener add 1 tiny drop of black pigment to the epoxy till the color is close to matching
#4 clamp it up (Assemble it) all pieces where you want them
#5 wait a couple of days for the epoxy to fully cure.
Dis assemble it (since you used release agent you can)
this is a great way to fix something like this or make a hidden tang knife that you can actually take apart without any big problems (if you wanted to).
good luck to you i hope this helps.

Sweet. Will give this a try. Thank you

 

[AVigil]

Sees to me I'm on about my third try but haven't had much success with the debonder, Adam. Maybe time to try again. Thanks.
Frank

I puddle it on and let it set until it turns the glue to a gel, then wipe off and if there is any remaining I do it again.

For me it has become a necessity when working with CA, using acetone also does work but evaporates quickly and can bugger some materials.