how do i make a guard

[legato1]

I forged out a big bowie and have a piece of walnut for the handle but have no idea what do do for a guard, ive made alot of knives with cord wrap handles and wood or micarta handles without guards, but this one is a small tang and i have never made a guard, i dont have a mill or anything like that, is there anyway i can forge the hole in the guard? will it still fit and look as good as the ones yall cut out with a mill.

 

[James_Terrio]

Is it a narrow or full tang? Regardless, TKS (and many other sites) has several types for sale; if nothing else, looking at them will let you figure out how they're machined. I just use a drill press and small files.

 

[legato1]

its a narrow tang, what type of files do i need and where do i get them? thanks guys

 

[James_Terrio]

Jeweler's files like these are handy for removing the webbing between the drilled holes and squaring up the corners. I had a cheapo $5 set from HF or somewhere and they wore out fast, so now I have some small Nicholson flat and round files.

I ground down the profiles so they'll fit in the holes/slots. I ground blind or safe edges on some, and sides on others, so I don't dig into the bottom of the slot when working on the sides and vice versa.

I've heard you can use a mill bit (?) in your drill press if you're gentle, but never tried it. If you have a Dremel, there are lots of cool little bits available for them that would get you in the ball-park. But without a proper mill, I think you're always going to end up hand-fitting them with files.

Remember, it's real easy to suddenly realize the slot is too big and then you have to start over. Check the fit often when you start getting close to size.

There's got to be a tutorial round here somewhere, I'll see if I can find it.

 

[James_Terrio]

Here's one by Tim Zowada.

Soldering a guard by Bruce Evans

Guard-fitting by Phillip Patton (the whole thread shows one of his bowies from start to finish... very cool!)

Another tip I found while looking for tutorials is this: Instead of using a series of center-punches to mark the drill holes, use a cold chisel to make a straight line a couple thousandths deep. That avoids getting the holes slightly out of line. Man, I wish I had known that a while ago!