How to radius corners on flat G10 scales?

P

Paladin Knives

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Jan 17, 2020
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Exploring how to round/put a radius on the outside corner on some 0.125” flat textured G10 for thin low profile handles on a 3/16” fixed blade design. How are you all getting this done for a scale design with curves and inner radii so that the finished corners are consistent?

I am looking at a Dremel 231 Shaper Router Table as one possible solution. Also looking at a tapered grinding stone as another.

Did some searches here and other places. Maybe I am not using the right search terms.

Thanks for any suggestions!
 
Depending on your grinder setup, you could use a small wheel and an angled work rest. That's what I do, but I also don't have any really small inside radii.
 
Thanks Michael:. No grinder yet, I am doing everything by hand at this point . I do have a good drill press and a Ridgid oscillating sander. Looking for a method that gives consistency.
 
If I was going to be doing a bulk of them a router and jig setup would be the go.

For just a couple I would just freehand them in with the small wheel and slack belt, or in your case a half round file and strips of sandpaper. If you go soft and slow you'll be able to get damn good results by eye
 
Obviously a router table or jig is the way to go. As hand alternative - file work + sand paper. Draw some line both sides of the corner and the radius curve at the butt and front of the "bolster" area. To be consistent brake the corners on 45 angle, and then brake the corners of the 45 one more time. If you file it, it is easy so see if you have consistent lines and you can correct as you go. On the curves you will obviously need to work with half round files. Round off with some stiff and coarse sand paper. I find it helps to angle the file to the work as to have more contact area and work on all the length consistently, not file at one place to much. Its kind of similar to blade grinding if you think about it. Try on a scrap piece first, shouldnt take more then 5 mins per corner and you get to practice your file work.
 
I do this all the time with a small bench top router. The biggest problem I run into is that the guide bearing on my round over bits is too high for thinner knives and handle materials, so in those cases, I'll make a thicker "mock" handle to fix the scales to and use that as a guide for my guide bearing. I use press fit pins to hold the scales, and then after routing the corners, I can pin and glue, or fasten to my blades as needed.
 
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