Kukri Handle...

fedaykincmndr

fedaykincmndr

Joined
Aug 3, 2004
Messages
971
So I purchased an authentic kukri from Nepal and from a reputable manufacturer who shall remain nameless for the sake of honour. As excited as I was, on the first outing (overnight, 5mi hike, 800ft climbs) the handle came completely off (see below). So, I decided to attempt to replace the handle as the blade was wonderful. Unfortunately, I'm at an impasse; I used an old hickory ax handle and the shape was perfect and other than a little splitting (remedied by rawhide and JB Weld), all was well. Upon some moderate chopping, the same thing happened ( I used JB Weld to secure the handle onto the tang). Attached below is tang (only about half an inch was cut off, and I really wish I hadn't done that), and I would like some opinions on what can be done. I really love this knife and I want it to work well, I'm just out of ideas. Thanks in advance, and yes I have contacted the seller and they said that because of the handmade nature, these things happen but I can get a discount the next time I order. I don't have the money to order another, and nor do I want to. Thanks again.

Modified

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Post Hike

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That tang should have been peened to the keeper/butt cap. If the tang is breaking, it's hardened and shouldn't be. I would really like to know what company it came from. I'm sure I could guess. I see no problem throwing them under the bus. Not all Nepal kukri are equal. By the customer service you received, I can only assume it was NOT HI. I would email HI and see what Auntie has in stock or watch the HI forum around 1:30 to 2:30 CST for the Deal of the day. Auntie usually has one three or so days of the week. Your experience will be totally different I assure you. Good luck and take care.
 
If you can get a drill through it(the tang)you could pin the handle.Along with your JB weld or 2 part epoxy,it should hold.
 
Many traditional khukuri had blind tangs. I have several. Some of the tangs were not nearly so long as yours.

They were secured by a glue made of tree sap and ???. Seems to be sort of like tar. It would gradually harden and require re-gluing. The folk apparently looked upon that as part of the game. Life is not without risk, and all that.

If you drilled the tang and put in some cross pins that stick out perhaps 1/8" on each side of the tang and then insert it in a wood handle using an adhesive that stays flexible (Show Goop?) that might serve. Or you could buy a thread-cutting die and thread it for a standard-thread nut. It ought to be soft enough to cut threads. That nut might need to be recessed in the butt since you have trimmed the tang a bit.

Such projects are discussed in the HI forum. May get better advice there from wiser heads who do more tinkering.
 
The tang is annealed (I have some exp forging and what not); so theoretically I could pin it and I was considering that. However, the problem comes with getting the tang in the handle and it not looking like garbage...any thoughts? I had considered heating the tang a bit just on the tip, and stretching it with a little hammer work, but I'm afraid that may take the HT out of the blade. Then if I could heat it I could tap it like you said Mr. Linton.

Anymore help is greatly appreciated.
 
Here is what I would probably do, and have plans to do whenever my khukuri handle goes kablooie.

Make a threaded extended pommel piece out of brass, copper, wootz, whatever kind of metal.
Then put on a bored handle, fill the void with epoxy or urethane caulk(NP-1), screw on the pommel.

I have done a couple of knives like this. One with cherry wood, one with Axis antler.

I have also done a hidden tang with pins through antler.
But in my thinking a chopper needs a more robust handle than that.

My two cents anyway.
I have some pics if you're interested.
 
If you have forge skills, you can weld a piece of threaded rod as long as you need onto the end of the tang.
 
As an update, I had a friend weld a piece of mild steel onto the tang and then peined it onto a metal endcap with "soft" mixed JB Weld in the handle (as much as I could get in). The trouble is after I literally beat the bat snot out of it chopping, there's about a millimeter of lateral movement (maybe less). I can really only feel it when I shake it side to side after chopping.

My concern is, will this affect the integrity of the blade or tang? Thanks, gents for all your help.
 
I took mine apart to try and replicate the problem and to re-handle, as the handle on it is too slim for my hand,
Working on mine presently and will post after I have it done.

I ended up welding a piece of all-thread to the tang. Last night I silver soldered a cross guard on it.

The laha is interesting to work with.
I wonder if mesquite tears would work the same way?
 
The peining worked well, it's just the slight lateral play that worries me. My hunch says it's not a big deal but I've been wrong more times than I'd care to admit.

I'd love to see pictures Cicatriz, if'n you have the time.
 
Well, and you do NOT want to be wrong with a blade that heavy!

I might be tempted to drill a small hole through the wood handle near the forward end, and use a syringe to inject a flowable epoxy into the gap, just fill it until you can't get any more in. Once it sets, it should conform to both the wood and the tang, just like bedding a rifle.
 
Komitadjie said:
Well, and you do NOT want to be wrong with a blade that heavy!

I might be tempted to drill a small hole through the wood handle near the forward end, and use a syringe to inject a flowable epoxy into the gap, just fill it until you can't get any more in. Once it sets, it should conform to both the wood and the tang, just like bedding a rifle.
Click to expand...

That sounds like a first rate idea.


FED- I'm pretty busy at work so it will take me a while to get anything done.
I'll post pics when I can.
 
I got the handle started this afternoon.

What I started with
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Tang after a good wire brushing. I tried to thread it but the metal is too soft and it ended up turning and snapping off about 3/4inch.
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Piece of wild cherry I cut off my supply log
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Handle rough cut
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Handle filed out and ready for sanding(I'm out of sandpaper)
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I almost stopped right here, this would have been an awesome club.
About 26 inches of square cherry past the handle.
Didn't get a picture of it because I was waving it around and scowling at things.


Brass cross guard soldered on and all-thread welded on(this was done a couple days ago)
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I finished the CS Scimitar and got this far with the Khukuri handle in about 4 hrs. Not bad I guess. When I'm in the shop time flies!
 
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I just got the handle fitted. Kind of a pain, but it fits pretty nicely.

I'll work on it and post more when I get some time.

FED- Did you get yours fixed?
 
Got the handle glued and the pommel screwed on.

I ended up using Gorilla glue.
I haven't had time to use the Khukuri heavily so I'll see later if it comes loose...

After the handle was finished I sloshed water through it, shook it out and filled it with glue, inserted the handle, squirted in more glue.
Used a thick leather washer and regular nut to keep the handle clamped down to the cross guard.

Waited a few hours, cleaned up the dried glue, sanded again and walnut oil for a finish.

Concerning the Gorilla glue.
I have always used Epoxy as my glue of choice for any dissimilar material bonding.

I have used G g for many of my projects for wood to wood bonding with excellent results.
I have also used it for metal to metal bonds with decent results. If big bubbles occur then all is lost.

Recently I read quite a few different knife making articles where they used G g with very good results if they over filled the void and prevented any expansion escape.
Supposedly the glue will penetrate deeper into the wood and hold onto the tang better that way.
I guess time will tell on this one.

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Hopefully the next pics can explain why I extended the handle a bit.

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It didn't come loose!!! Gg worked fine!
Abuse test through a 2x6 and then started on a dried/cured oak log.
Failure set in....
The tang bent in front of the weld and the handle broke near the guard...

The glue held tight, but as the tang bent something had to give, so the cherry sacrificed itself on my behalf....
I will miss you dearly sweet cherry.....sniff
FULL TANG FOR ME ON ALL KHUKURI!

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I plan to throw this into the nearest active volcano... Too bad there aren't any near me.
 
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Absence of volcanoes in an area is often attributed ti absence of virgins. At least that's what the guy from A&M told me about the Austin area.
 
Nice handle, thank you for sharing
 
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