How to cut a small hidden tang slot?

[Fish30114]

I decided to make several small 'cheese knives' for some of the craft shows we attend and I didn't think it through a lot I suppose, but I ended up with tangs that are about 1/4" x 1 1/2" and only about 1/16" thick. I can't figure out how to cut this small of a slot into the handle material. I suppose a 1/16" drill bit is where to start, but I don't know how to open up the slot to 1/4"

Any advice/tips are appreciated-Thanks,Don

 

[comet_sharp]

I do this for my handles. Finish with a micro rasp if I need to enlarge.

 

[Fish30114]

Thanks--are those sabre saw blades or what?

 

[comet_sharp]

Yes, the 2 on the left are sabre saw blades and the one on the right is from a small hobby hack saw. I just ground them down. These are all for 3/32 stock.
I'll probably make a handle for them soon, just been busy and it hasn't really bothered me.
These guys also work amazing, I connect the holes with the small saw blades then fill in as needed with the rasps. The bigger saw blade I use to expand the hole if needed.
http://www.micromark.com/Needle-Rasp-Set
https://www.woodcraft.com/products/needle-rasp-set-w-handle
I use the micromark set because I was on a budget but will be grabbing the set off woodcraft soon. For the price, the micromark have cleared out a good amount of african blackwood blocks..
-Trey

 

[Fish30114]

I wasn't aware of the micro rasps, I will definitely be looking to get a set of those!

 

[Stacy E. Apelt - Bladesmith]

By far, the simplest method is to drill two holes that are about 75% of the desired slot size and cut out the material between them with a jewelers saw. After a little practice, and slot size can be cut in a minute or two. After the slot is cut out, file it to a perfect fit. One piece of advice is to lift back the saw a tad on the return stroke. "Sawing" back and forth with these small blades will kill the teeth in a dozen strokes. If a blade stops cutting well, or wants to cut in a curve .... replace it right away. Lubricating the blade with a little candle wax is also a good idea.

If slotting a deep bolster block, like the ones Comet showed, mill/rout out the back side so you are only slotting about 1/4" of wood. I do this on thick metal guards, too.

Try #3 blades work good for soft metal, #1 for steel, and #7 blades for wood. From there you can go to whatever blade size you feel comfortable with.

 

[Natlek]

I decided to make several small 'cheese knives' for some of the craft shows we attend and I didn't think it through a lot I suppose, but I ended up with tangs that are about 1/4" x 1 1/2" and only about 1/16" thick. I can't figure out how to cut this small of a slot into the handle material. I suppose a 1/16" drill bit is where to start, but I don't know how to open up the slot to 1/4"

Any advice/tips are appreciated-Thanks,Don

I tried several times and did not like how it turned out , slot was to wide and I don t want to use metal bolster / that is probably even more complicated to do that thin..../ Probably I do not have the necessary tools so I solved the problem like this .......Two piece wood , tang between them pressed hard and glued in this tool ............come prefect , no visible gap between steel and wood /walnut/ .Steel is 1.5mm thick

 

[Fish30114]

Good intel folks, thanks for the scoop Stacy, I will try some with that methodology.

 

[Fish30114]

I tried several times and did not like how it turned out , slot was to wide and I don t want to use metal bolster / that is probably even more complicated to do that thin..../ Probably I do not have the necessary tools so I solved the problem like this .......Two piece wood , tang between them pressed hard and glued in this tool ............come prefect , no visible gap between steel and wood /walnut/ .Steel is 1.5mm thick
QUOTE]

Cool looking clamps there, where did you get them?

 

[Natlek]

I tried several times and did not like how it turned out , slot was to wide and I don t want to use metal bolster / that is probably even more complicated to do that thin..../ Probably I do not have the necessary tools so I solved the problem like this .......Two piece wood , tang between them pressed hard and glued in this tool ............come prefect , no visible gap between steel and wood /walnut/ .Steel is 1.5mm thick
QUOTE]

Cool looking clamps there, where did you get them?

From old heavy truck cabin lift air pressure cylinder ............Something like on the picture ,not exactly that but similar ............I m mechanic