Help me with concealex!

Chief_Wiggum

Chief_Wiggum

Gold Member
Joined
Jan 19, 2003
Messages
306
Hi all,

I'm hoping a sheath guru can help me. I just threw away 4 concealex sheaths I pressed for my Busse Assault Shaker tonight. I'm using the cf pattern concealex, and my main problem seems to be pressing it.

I have 2 3/4" pieces of plywood with 2 1" pieces of foam sandwiched between them. Between the foam, I have two more pieces of 1/4" closed cell foam sandwiched. I use c-clamps to press.

I tried temps between 200 and 300 degress with times ranging from 2 - 3:30 minutes.

The problem seems to be that I can't hit the "sweet spot" for temp/time to press the sheath. Also, the area immediately around the knife outline doesn't come out perfectly flat. Rather it has gentle waves that I just can't seem to flatten out.

Anyone give me some tips for working this material? I would really appreciate it.
 
On small knives I just heat the stuff up with a heat gun till its good and flimsy.. Then I slap the knife in, position it, and clamp it in the vise GOOD and tight, and let it cool.. I dont have any problems.. Maybe its the foam you are using?
 
Trace,

At this point, that's what I'm thinking. I have to order some better stuff, I guess. Thanks for the reply.

Now about that Gambit I've been wanting....:)
 
Hi Chief,

I have had best luck with heating at about 300-350 for 5 minutes on Concealex. (that's in a conventional oven)

I also use 2 coarse dish towels (the kind without a lot of lint) on either side of the Concealex and place the whole thing on a cookie tray.

Concealex has a tendency to roll a lot more than Kydex and the towels help prevent that, they also help to minimize scorching.

I would also consider a different clamping mechanism, sounds like c clamps would take a little too long to get ligned up and clamped down. They may not deliver the pressure you need either.

Foam wise, may want to go a little thicker - I use 1.5" - 3" on either side of the blade based on the sheath I'm making.

FWIW, I think Kydex is an easier sheath material to start out with because it's a little more forgiving. I've made probably 600+ sheaths and probably only 50 or 60 in Concealex.

Also, don't get discouraged, I probably threw away 20 sheaths when I first started making them before I got one I was happy with!

Good luck!
 
Hey Chief..

I'll tell you what you are doing wrong..

Ok here's what you do...

On your plywood molds laminate to pieces of 3/8" sleeping pad foam...

!" each side is fine as well..

Loose everything else...

The more foam you use, them more pressure you are going to need..
1-2 C clamps probably won't cut it...

Heat your concealex with a heat gun.. Get rid of the ovens and any other contraptions.. You need to get a feel for your work.. You won't achive that slapping a piece of hard plastic into an oven and looking at your watch... Learn to feel if the plastic is up to molding temp.

The reason you aren't getting a crisp outline is because you aren't using enough pressure.. If you use C-clamps, place a pice of steel inbetween your clamps and mold.. This way they aren't digging into the wood.

Torque the hell out of them, and work quickly.

Adding acouple of 2X2 feet onto your bottom mold will make work easier,,as will a Quick clamp, just to hold everything into place...

If you are doing only a couple of sheaths at a time this type of set up is Ok. If you are doing them all of them time, you may want to look into something a little more durable.

It's Rinky dink,, but will get the job done...

ttyle

Eric...
 
Thanks for all the advice guys. I asked for sheath experts, and I got sheath experts! How cool is that?

All the suggestions you guys have made were right along my line of thought. Buy a heat gun, get some better foam, get some better clamps, make a better press. It's always easier to listen to someone else's advice, I suppose.

I'm going to spend this weekend goofing around with some new parts. Thanks a bunch guys.
 
Chief...

Remember..

Steady downward pressure is going to make a world of difference....

You also want to make sure you aren't flexing the molds...
A Thin mold base is going to be your worst enemy...

Couple of chunks of 2X8 will solve that...Glue your foam down right to the 2X8's..

Have fun and burn your fingers..:)

I've got burns, Ontop of burns!! :)

ttyle

Eric...
 
FWIW, I use a shop vise, 2 pieces of 3/4" plywood and my foam as a press. The whole thing is done vertically and can be clamped extremely fast.

If you still have trouble with the C clamps give the vice a shot.

I also use a pair of brown cotton work gloves to ease the pain :) I still have burns but not quite as bad!
 
Hey ovens are GREAT!!! Especially for something like my Armageddon sheath which is made from .125 Concealex... Trying to heat those things evenly with a heat gun is futile... Just depends on what you are making..
 
Hey Trace...


Ohhh Yaaa!..

In a case like that when having to heat a large slab, then it's the only way..
I'm just talking about small projects in the .060-.090 range...

ttyle

Eric...
 
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