Help, how to cut these tight curves?

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Brian.Evans

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I've got an idea for some bolsters on a knife a bit out of my comfort zone. I need to cut these curves in wood and g10 or linen/paper micarta. Any ideas? To get it exactly right I will have to stack layers: scale, bolster, bolster, scale. So, if everything is a 1/4" thick, I'm looking at 1" thick worth of a stack. Will a jewelers saw work? If so, any links to a decent saw and blades? I want to buy something middle of the road. Cheap tools don't pay off, in my experience.
 
Yeah....helps if I post the picture, huh?
 

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Jigsaw, thin blade, small teeth.
Use slow speed and take your time...
Otherwise, I think Harbour Freight or the likes have a type of table saw for cutting wood.
Like an airpowered jewelers saw. Used for cutting out lettering and small figurines.
 
I would not cut it out in a stack like you are hoping to do. I think you will have a very difficult time getting a clean fit unless you are going to use a flexible spacer material the same thickness as the blade kerf. I tried Weldon Whitley's technique for curved bolsters and it worked really well for me. I think that would be the best technique for your design. You can get a good idea of how it works by looking up the preview video on youtube.

Bob
 
How about making both stacks a bit long, drilling round holes to start the "inside" curves and then be a sawing and filing fool?
 
I totally agree with Ranger Bob. :)

Shy of a wire EDM cutting out the two mating parts, I don't think you could ever cut that type of joint and be happy with the resulting fit-up.
 
Well, then I'll do it the right way. Dang. Thought I had figured out a shortcut. Oh well. :)

Nick, feel like a tutorial?? :)
 
Cut and finish profile the metal parts, then scribe them onto the scales and cut the scales just to the line, then hand fit with files.
 
Have you considered a pattern routing technique? It may work if the radius of the curves aren't to tight for the size of the rub collars.
 
woodwrkr221 said:
Have you considered a pattern routing technique? It may work if the radius of the curves aren't to tight for the size of the rub collars.
Click to expand...
Well, that might work, but the rub collars would have to be pretty small. I think everybody is right. Cut and finish one piece, scribe, cut big and file to shape for fit.
 
The more I think about this I have a copy of this video, haven't watched it in awhile:

http://www.knifemaking.com/mobile/Product.aspx?ProductCode=VL122

In this video, Weldon Whitley uses a steel pattern he made himself and a rotary file in a drill press with the smooth portion of the rotary file rubbing on the edge of the pattern. He carves the edge of his bolsters with the rotary file then he flips the pattrrn over, it must be symmetrical I suppose, and uses the same pattern and rotary file to carve the edge of his mammoth ivory scales.

Do you suppose this would work for your's?
 
But the question is how do you make the pattern? :D
 
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