M A S S I V E recurve bowie *WIP*

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Mark, I told you that CF was tough stuff. That's why we use it to make Formula 1 race car chassis and that stuff I sent you is the BEST.
 
Ok guys, sorry for the little reprieve. I had been traveling to Blade (which was awesome!!) Met so many of you peoples :D

Also i've switched from photbucket to imgur. Shouldn't mean anything for y'all, i just couldn't stand the archaic pace that crapbucket moved at...... :p

So here is a bit of progress i've made since then.

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Here i began to scribe and layout the holes and whatnot for the spacer. Decided to go simple and understated since the attention is going to be focused on the wicked carbon layup done by Big Rick!

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Cutting out the spacers with the jewelers saw. I can get it fitted with very minimal filing with a good blade and saw.

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Fitted!

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So i took my original drawing and made a photo copy of the handle. Printed it out, cut it out, and layer it against the tang... Makes life easy

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Then i glue the paper template to the handle block. as you can see there is some material that needs to be removed...

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Then i grind my angle in which is pretty self explanatory. HOWEVER, not saying i did this.... but make sure your platen is square people! Or else you'll have one hell of a time down the road. I "knew" a guy who did this and he wasn't very happy :grumpy::rolleyes:

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See now the tang is aligned in the center of the block, so i trace it and find where i need to drill my holes.

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Holes drilled! I use those long spiral twist drills... very technical procedure :p

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Here is one of my sawzall blade broaches. Now i don't have a fancy broach made by Bump or Perry, although i wish i did, but i would not use it on carbon fiber because you WILL destroy it. Carbon fiber is very keen at dulling blades. i went through 8 sawzall blades after things were all said and done....

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And you just play connect the dots, in theory at least :D

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Yup, thats good! :p

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A tip on fiting tangs; coat your tang in sharpie and slide it in, where its catching will show up... I'm sure i picked that up somewhere here on the forum, probably from Wheeler i dunno :cool:

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SO, after fiddling around with this for two and half solid days. I became frustrated with my progress and decided to make the "MegaBroach9000" just look at its 9000 carbon hungry teeth of destruction!
(*sorry cold steel i have that patented)

And it did the trick. :o
Typically it takes me maybe 30min, at leisurely pace, to fit a handle. However this stuff was not having it!
Next time i work with carbon hopefully i'll have a mill and some quality carbide 6" long end mills....

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SO here it is all fitted and profiled! yay!
Doesn't seem like much but stuff like this takes me awhile; from now on out it should be smooth sailing.
I will more than likely shorten the handle just a tad... keep in mind i don't profile it to exact spec at this point so that i'll have some insurance later on.

Whelp thats all folks. Tomorrow i will clean up the fit, drill my pin hole, finish the guard face, finish the blade (hamon polishing etc..) and if all that goes well.... have it glued up!

thanks everyone for following along, its been taking me awhile and i do appreciate your generous attention spans :)
-Mark
 
Nice work, that is going to be a beautiful blade when your finished with it. Love the Dachshunds, ive got a black and brown myself, they make great assistants...lol
 
Mark, you have my upmost respect using that hand broach For a job like that we would use diamond coated or solid carbide cutters. You will find sanding is a piece of cake now, wrap these arms and hands upwelling or you will itch for days.
The knife is coming along real good and getting excited to see this one finished. Great WIP, thanks for taking the time to do it.
 
Brilliant WIP. Thanks for taking the time to share it.
Brings back some painful memories of slotting guards before I got a milling machine!
Superb work.:thumbup:

Ian.
 
getting closer guys; I know I'm pretty slow.... but I'm having a blast!

SO.... I worked on finishing the face of the guard. Typically i just rub it down on sandpaper glued to granite, but this one got all bent out of shape.
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I went ahead and put an edge on the clip too. I did this because i didn't really want to risk messing up the finish after having spent hours etching the blade to reveal the hamon. Should make hand polishing exciting :eek:
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Yes the Clip is VERY sharp! just ground to zero and stropped on my ghetto, although effective, 2x72 stop thingy

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Then i take the blade up to 2000 grit by hand.... you know so i can etch it..... :(
But thats Hamon Lyfe!!!!!

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Etch my logo... "LongDog" AKA Weiner dog AKA Dackle AKA Dachshund AKA perro salchicha.

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Alright now to get the party started! Here is what i'll be using to bring out the hamon. I use a variation of what Nick Wheeler does (just as he has shown many times here on the forum) using multiple etch/polish cycles with vinegar. Its a much slower process than using ferric, altogether took around 5 hours non stop, but i like the look of it :)

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here is what the knife looks like after a 7-10 minute etch with vinegar... Like a TURD.

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SO you take liquid silver polish (most people use FLitZ) and polish off all the oxides. This is a two steps forward one step back type of deal. You etch the hamon bringing it out, then you slightly rub it away when you go to remove the oxides. It takes about a dozen Etch/polish cycles to get a good outcome.

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In-between etch cycle i completely degrease the blade with hot soap and water. If your hands begin too look like prunes, then your doing it right!

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SO after a long time of etch/polish, i polish the blade some more! this time with 1500 grit silicon carbide powder, some 3 in 1 oil and my fingers. Basically you polish until your either tired of polishing or happy with the results; whichever comes first. very high tech.

After all that you should get something similar to this.
Excuse the terrible photos, as y'all know taking photos of hamon's is a total PITA. i'll leave it to the pros!
However, i'll do a video overview once the entire knife is done.
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I'm most pleased with how the body of the hamon wrapped the clip! last time i had issues with it running off the edge (no bueno!) however this time.... life is good!

Alright, now for boring photos....
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G-Flex cuz its the best. end of story :cool::D

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And its glued up! Since the knife is huge, it wouldn't fit in any of my jigs i'd typically use to clamp knife together with. So i heard of guys using super glue to tack the blade in place while the epoxy sets up. It was a little precarious but once i got it in place it held like a rock. Not bad!! i may have to use this method again...

I've got a hard bike ride in the Texas hill country tomorrow, so thats all from me folks!
The end is near, alls left is handle shaping.... and I'm S T O K E D!!!! :D

thanks everyone,
-Mark
 
So i heard of guys using super glue to tack the blade in place while the epoxy sets up.

Where do you tack the blade?

I'm thoroughly enjoying this thread Mark. That piece is looking very nice.
Thank you for sharing your process.

-Peter
 
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Where do you tack the blade?

I'm thoroughly enjoy this thread Mark. That piece is looking very nice.
Thank you for sharing your process.

-Peter

Just on the outer 4 corners of the guard. Much like how you would tack something together with a welder.
Some guys use the super glue on the inside to hold it in place, i just wanted to try it this way :)
 
Alright here is a brief set of photos of the handle shaping. I didn't take a ton of photos because i zone out while doing this...... I don't really have any tips or tricks for this part of the process, guys like Wheeler and Morrison do a much better job at explaining the techniques (many of which i employ), so go check em out :D
I just walk up, turn some loud music on, and get to grinding!

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First i take the handle down to the flats of the guard.

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Using files i'll carve in my guard-to-handle transitions. this is a pretty crucial area to get right!

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then i smooth is all out with the slack belt and different grits. My favorite belts to use (not pictured) are 1" scalloped 220 grit belts. I use the heck out of them for all types of stuff!

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When shaping handles its paramount to flick the knife around in your hand, play with different grips, fight invisible adversaries etc..... Because when things are all said and done, you want the handle to be comfortable, and the best gauge for that are your hands!
(ps. i ran out of gloves...)

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And here is a shot fresh off the grinder with an all around 220 grit finish. I'll take it to 1500 grit by hand and then finish the sides of the guard.

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A shot during hand finishing. Normally my bench is neat and tidy, but during finish work things get thrown all about!

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Making sure things are lined up well... also the booty is rounded over; no flat asses here :D:cool:

finishing the sides of the guard....
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Finished pics will be inbound this evening!!! I've only got about and hours left worth of work in it.
After that its sheath design.... I'm going with a full Baldric rig!!!

thanks everyone for staying plugged in :cool:
-Mark
 
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Supremely Entertaining

Great to see your equipment in use. (Looked like a Bessey clamp in one shot)

Thanks also to the one who commisioned this Work of Art.
 
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