How to cut the slot for angled guards?

[Patrice Lemée]

I took a few pics to try and explain what I mean.

Do you first cut a regular perpendicular slot like this:

And then remove enough on one side (green area) to flip the guard at the right angle like this:

Or just cut the guard angled like this:

The second option looks like the best one to me but I am afraid that cutting that angled slot is much more complicated than it seem.
PS: I use the mill to cut the slots and finish by hand.

How do or would you do it?

Thanks

 

[Mike Turner]

I would do like in your second option and would draw the slot line like you have then just lower the cutter down and line up the lines to the cutter and clamp it in your vise. Of course you will have to extend the lines around to the face that is facing up so you have your start and stop and finish with files.

 

[Stacy E. Apelt - Bladesmith]

What I do is a modification of number one.
Start with a slit that is about 75% too small. As you file the angle in go up on the top front and down on the back bottom edge. This will tilt he guard and open the slot to end up like number two drawing. If you draw perpendicular lines from the guard edges at the points where the ones in number are now ,You will get the starting drill points for the slot.

 

[butcher_block]

i mill undersized then reset on angle to start more milling but then finish with files for a tigght fit up

 

[sunshadow]

I would do number 3, clamp it in the milling vise at the correct angle, use slightly undersized centercutting endmills, and plunge it a quarter inch at a time slightly undersize and file to fit

-Page

 

[Patrice Lemée]

I'll give no.3 a try then. I'll try Stacy's way if it doesn't work. (my milling skills are sadly well below par).

Thanks guys.

 

[Sam Salvati]

If you got a mill, just set the guard piece angled, then plunge and cut the slot angled.

 

[Mike Turner]

It also helps to drill out the bulk of the material that needs to be removed firt before using the end mill bit.

 

[NickWheeler]

I would do option -1 and put the guard on perpendicular to the blade. Unless you angle your plunges on the grind, I think a slanted guard looks off. It also screws with what you can do with the handle to guard junction as you are instantly "pinching down on" the area where the index finger goes.

I did make some angled ones before I came to this opinion.

 

[Patrice Lemée]

I did make some angled ones before I came to this opinion.

Guess I'll have to do the same.

I'll pre-drill first. Thanks.

 

[Stacy E. Apelt - Bladesmith]

Patrice.
I didn't know you were milling the slot. Just follow Butch's advise. It is the milling version of my drill press instructions.

 

[Patrice Lemée]

Guard still not fitted after about 3 hours of work.
Should have listen to good ole gram-pa Nick!