Help, how to cut these tight curves?

[Brian.Evans]

What about taking it to a water cutter? a good one could easily slice through everything you have.

Nah, it's not worth all that for a one off. I'll just cut out one and file the other.

 

[Stacy E. Apelt - Bladesmith]

I would suggest it be done on a CAD controlled milling machine. The same program would also cut the scales to fit. Use a proper size and type mill bits and it should fit seamlessly. Once the program is designed and written, it can be repeated as many times as you wish on future knives.

 

[woodwrkr221]

Nah, it's not worth all that for a one off. I'll just cut out one and file the other.

Yep, for a one off that's the answer. If you were making multiples or offering this on a regular basis then the cad/cam or machined pattern ideas might be worth the extra effort and expense.

 

[Brian.Evans]

I would suggest it be done on a CAD controlled milling machine. The same program would also cut the scales to fit. Use a proper size and type mill bits and it should fit seamlessly. Once the program is designed and written, it can be repeated as many times as you wish on future knives.

Sure, know anybody?

 

[Stacy E. Apelt - Bladesmith]

Bran,
I was sort of being tongue-in-cheek. That would be how to do it right. Any knifemaker who uses a CAD mill, or any machine shop should be able to do it. The cost of doing only one would make that not a real option.

I would just use the best methods your shop has to layout and cut the pattern in the metal, then hand fit the scales. It may take a couple of misfires before you get a good fit. The trick of drilling holes at the valleys of the serpentine patters is a very good idea. Use a jewelers saw or the band saw to cut out the rough block and shape with straight round files ( no taper).

I will give you this tip;
Shape the pair together once the basic bolsters are cut out. Drill them for the rivets ( no tapers or chamfers now) and temporarily peen them together with brass rivets......just enough to keep them snug. Clamp in the vise and file to shape. After filing them to shape together, just file/grind the peened part off and pop them apart with a sharp knife blade. You will have mirror matched left and right bolsters. Doing it in double thickness also prevents getting angles in the serpentine.

 

[Brian.Evans]

Stacy, I knew you were just messing with me. I was messing back.

Thanks for the tips. I pulled out the design again tonight. I'm not sure I like the wavy junction anymore. I'm not sure what to do with it, but I don't think the curves fit.