Hidden Tang Bolster How-to

H

Harley Boatman

Joined
Jun 21, 2020
Messages
98
Hey guys,

I'm trying to make a hidden tang meat carving knife and I'm finding that when I try to hollow out the handle block, I'm accidentally making the hole too wide so it's not a clean fit.
I was going to do real thin copper bolster to try to hide it, but I just can't figure out how to get it to look clean. (I figure since copper is harder than wood it shouldn't file away so easy)

The method I'm using is marking where the tang will go, then drilling, then filing with small files and sawing with (ground short so they fit) reciprocating saw blades.

What's the method to get the bolster as clean as in the photo? It looks like it fits the tang so perfectly.
<blockquote class="imgur-embed-pub" lang="en" data-id="a/V7ezlQg" data-context="false" ><a href="//imgur.com/a/V7ezlQg"></a></blockquote><script async src="//s.imgur.com/min/embed.js" charset="utf-8"></script>

Thanks!
 
Harley Boatman said:
Hey guys,

I'm trying to make a hidden tang meat carving knife and I'm finding that when I try to hollow out the handle block, I'm accidentally making the hole too wide so it's not a clean fit.
I was going to do real thin copper bolster to try to hide it, but I just can't figure out how to get it to look clean. (I figure since copper is harder than wood it shouldn't file away so easy)

The method I'm using is marking where the tang will go, then drilling, then filing with small files and sawing with (ground short so they fit) reciprocating saw blades.

What's the method to get the bolster as clean as in the photo? It looks like it fits the tang so perfectly.
<blockquote class="imgur-embed-pub" lang="en" data-id="a/V7ezlQg" data-context="false" ><a href="//imgur.com/a/V7ezlQg"></a></blockquote><script async src="//s.imgur.com/min/embed.js" charset="utf-8"></script>

Thanks!
Click to expand...
Also I guess I did the photo embed wrong again.. maybe this will work:
https://imgur.com/a/V7ezlQg
 
Fitting a guard/bolster begins way earlier than it's time to fit it.
First of all, you need to make sure the tang tapers width and thickness wise.
Once the tang is prepared, square up the shoulders with a file guide.
qyHAE9L.jpeg


Keep the shoulders nice and rounded to avoid any stress risers.
1vjUeSk.jpeg


Mark your tang and drill holes with a drill bit 1mm undersized.
7NpMvRZ.jpeg


Personally, on thicker materials I like doing some larger holes on the backside about 80% of the way to create a recess. It makes the fit a whole lot easier and later on it is filled with epoxy for a lovely moisture barrier.

GCVskmr.jpeg


Connect the dots with needle files or a rotary tool.

wf5P9Me.jpeg


Begin filling carefully and check the fit frequently, the goal for a tight fit is to file a bit undersized and hammer the guard home.
Qn6Sb1z.jpeg

Once you reach this stage, you will need to file carefully the contour of the shoulders.
5bPIcjN.jpeg


Do that and drive the guard/bolster home using a steel spacer to protect the underside of the guard and a pipe to hammer on.

jbnrX5h.jpeg

Hope that helps, feel free to ask for any further explanation.
 
Last edited:
Depending on how much oversize your slot is, before you toss it there are two things you could try,
1) put it into position, hold the bolster flat against something like an anvil or vice and hammer it down to close the gap to something you find acceptable.
2) place the side you will see uppermost on the vice or anvil and pein all round the slot, you may be able to move the material a mm or two then refinish the flat.

If you are still not happy make another.
 
Way-Barney said:
Depending on how much oversize your slot is, before you toss it there are two things you could try,
1) put it into position, hold the bolster flat against something like an anvil or vice and hammer it down to close the gap to something you find acceptable.
2) place the side you will see uppermost on the vice or anvil and pein all round the slot, you may be able to move the material a mm or two then refinish the flat.

If you are still not happy make another.
Click to expand...
Now I have tool who *cares * that I don't make oversized slot :) but before that when I somehow make mistake and oversize slot ...I keep that one for other knife whit thicker tang and make new one guard for knife I work on .No hammer ;)
 
A lot of practice also helps :P
Annealing the copper can help if you are cold forging it around the tang. I often cheat by soldering them

From my experience flat surfaces and cylinders are pretty easy, but a precise rectangle or similar is hard. That photo is shot from an angle that makes it harder to see the flaws. Not saying that one is bad, but makes it a little harder to see any gaps
 
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