Help please, pins won't fit hardened blade pin holes

[Natlek]

I have opened many holes with a diamond tip on a dremel tool.

That is simple and fast to do .I don't like advice sanding down the pins .What if after sanding you get Dia. which is nowhere close to any drill bits for holes in scale ?

 

[AVigil]

That is simple and fast to do .I don't like advice sanding down the pins .What if after sanding you get Dia. which is nowhere close to any drill bits for holes in scale ?

I agree.

It takes a few minutes to open up a hole with a dremel.
Sanding down the pin can cause an entire new set of problems trying to find a drill bit that size.

 

[scherf68]

I agree.

It takes a few minutes to open up a hole with a dremel.
Sanding down the pin can cause an entire new set of problems trying to find a drill bit that size.

AVigil What diamond bit are you using, the ones I have are not working very well?

 

[Scaniaman]

I had a round diamond needle file I put in my hand held drill, when I had this problem at one point. Gave me the clearance needed quick enough.

As for drilling oversized holes in the tang, I see no need to go bigger than 0.1 mm over pin diameter. The more oversized the hole, the more the pin and scales can/will move around during glue up and that can cause asymetry in the final results.

 

[Stacy E. Apelt - Bladesmith]

When these Harbor Freight diamond burr sets are on sale I get two. They are around $12 on sale. You may only get one or two uses each, but for the money that is fine.
https://www.harborfreight.com/50-pc-diamond-rotary-point-set-69665.html

 

[scherf68]

Thanks Stacey, will look for a coupon and pick up a set.

 

[fitzo]

Have a rotary tool? This cutter works great for opening 1/8" pin holes back up post HT, but takes a steady hand:

https://us.dremel.com/en_US/products/-/show-product/accessories/562-tile-cutting-bit

This page is all their cutters. There's a solution in there for 3/32", too. (9904 bit)

 

[johnfbkennedyy]

Thanks for the amazing advice to all again. I did try sanding down the rods: the carbon fiber rods were very easy to sand down, the stainless steel 1/8 rods were difficult to since I couldn't go high speeds on the dremel or it would bend because of the centrifugal force, the mosaic pins were a real pain in the but; I couldn't sand them down even at high speeds using tons of new low grit sand paper with a drill. After about an hour or so I noticed the pin wasn't reducing in size and since it was constantly being heated up (I tried my best not to by cooling it in water with ice constantly) the epoxy just started pouring out and it made a mess (someone also mentioned this would happen). I then gave a go the idea of using the dremel diamond bits to open the 1/4 hole, it was super easy and quick and that solved the problem. I would've wanted to do that for the 1/8 holes but I don't have a carbide cutter as many suggested so I had to sand those pins down. Maybe I'll get the carbide cutter bit for future situations as this was a very effective solution. Thanks again, just waiting on the epoxy to dry out but it looks like it was a success.

TLDR: Thanks for the ideas, sanding down the pins worked for the smaller pins but the mosaic pins were a no go, I opened the pin holes with diamond bits and it worked like a charm. It would be more effective to use the carbide cutter with dremel for smaller holes in future situations.