Mocking up a knife handle: how would you go about it?

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edgecentricity

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Feb 10, 2018
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If I wanted to mock up a knife handle -- something especially built to fit my hand -- to pass on to a custom maker, what would be a good, simple way to do it? I don't have access to shop equipment, so cutting something out of wood or plastic is a no-go. What about thick cardboard, maybe two layers glued together?

Apologies if this isn't the appropriate forum for this question.
 
Oh that's easy :
Buy and use a whole passel of knives from many of the styles and sizes available.
Narrow it down to three that you like. Provide those as positive examples.
Tell him / her the three that you just can't tolerate and why.
Turn 'em loose to make your knife.

If you want to get even more on target . . . BUY SOME SHOP TOOLS . . . fool around with them until you can do stuff without loosing too many body parts or bodily fluids . . . then modify the areas of the production kinives that are top three until they work even better for you.

Heck I was sawing, grinding and filing one today to get rid of the bits that weren't working for me.
PS :
Safety tip cover any exposed blade edge well enough you cannot possibly get cut or stabbed before starting to work on a knife.
 
Ah, the old buy 'em and try 'em tactic... :D True, that is probably the quickest (though regrettably, costliest) way to become acquainted with different handle shapes and sizes. I do at least have access to files, sandpaper, etc., and have put them to use before (like when I removed the flared section of handle from an ESEE Zancudo near where the handle meets the blade ricasso -- there was a bump there that added no apparent functionality, and dug into my thumb when using certain grips).

I'd like a Dremel. And a belt sander...

Thanks for the reminder to cover the blade edge. I've failed to do so in the past, and paid with pain and blood. Eek.
 
edgecentricity said:
If I wanted to mock up a knife handle -- something especially built to fit my hand -- to pass on to a custom maker, what would be a good, simple way to do it? I don't have access to shop equipment, so cutting something out of wood or plastic is a no-go. What about thick cardboard, maybe two layers glued together?

Apologies if this isn't the appropriate forum for this question.
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Get a hunk of clay and hold it in your hand comfortably like it's a knife handle! You will be amazed at the wierd shape! But if the handle size and shape is based on that!...:thumbsup:
 
LG&M said:
You don't need "shop equipment " get some soft wood & start carving . A half round file & some sandpaper would help.
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You're right, actually -- I'd never even considered that. Sandpaper, I have plenty of, and an assortment of files, too.
 
I'd do it with cardboard or styrofoam first, then maybe leather or wood.
 
edgecentricity said:
If I wanted to mock up a knife handle -- something especially built to fit my hand -- to pass on to a custom maker, what would be a good, simple way to do it? I don't have access to shop equipment, so cutting something out of wood or plastic is a no-go. What about thick cardboard, maybe two layers glued together?

Apologies if this isn't the appropriate forum for this question.
Click to expand...
Go to your local home improvement store and get the 1/4" thick paint stirrers. The larger of the two sizes at home depot.
While you are there grab a half round file (flat on one side, curved on the other) and some 400 grit sandpaper.

Grab the paint stirrer and close your hand around it, mark 1/4" beyond your hand width on each side. Mark between your fingers so you can make accurate curvatures.

Make a few different shapes and see what you like the best. All it takes is a simple hand tool and some sand paper. Hell, you could do it on a concrete curb if you wanted to.
 
I usually draft digitally in Inkscape (an open source vector drawing program) and then print at 1:1 scale, adhere the template to cardboard, and see how it feels. If there are obvious things that need fixing, I keep making adjustments until it's where I want. Then I move to a wood template to add the rest of the contouring to it and finalize the design.
 
NJBillK said:
Go to your local home improvement store and get the 1/4" thick paint stirrers. The larger of the two sizes at home depot.
While you are there grab a half round file (flat on one side, curved on the other) and some 400 grit sandpaper.

Grab the paint stirrer and close your hand around it, mark 1/4" beyond your hand width on each side. Mark between your fingers so you can make accurate curvatures.

Make a few different shapes and see what you like the best. All it takes is a simple hand tool and some sand paper. Hell, you could do it on a concrete curb if you wanted to.
Click to expand...

Thanks for the pointers -- I probably wouldn't have thought of using paint stirrers. I've got an assortment of files, and sandpaper (which I use for convexing edges).
 
FortyTwoBlades said:
I usually draft digitally in Inkscape (an open source vector drawing program) and then print at 1:1 scale, adhere the template to cardboard, and see how it feels. If there are obvious things that need fixing, I keep making adjustments until it's where I want. Then I move to a wood template to add the rest of the contouring to it and finalize the design.
Click to expand...

Thank you for the recommendation. I hadn't thought of using software -- nice to see there's something suitable and free out there. I'll have to check it out, and see if I can wrap my head around it.
 
Just saw this AR grip. Something like this would be a possible way to develop a custom handle.

1L.jpg

2L-1.jpg

3L.jpg
 
edgecentricity said:
That's pretty neat! Took me a moment to understand what I was looking at. It's like a high-tech version of... putty, I suppose.
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Yeah. All you need is a stack of washers, some redi-rod and a couple nuts The thinner the washers the finer the fit.
 
Danke42 said:
Yeah. All you need is a stack of washers, some redi-rod and a couple nuts The thinner the washers the finer the fit.
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So... help me understand this. Are you saying just take some threaded rod, put a nut on one end, stack a bunch of thin washers (whose holes are of a bigger diameter than that of the rod, loosely put on the other nut grip the washers, and tighten down the top nut? Something like that?
 
I have used silly putty. The same concept as using clay but maybe easier to source. Plus the colors are cool
 
FOG2 said:
I have used silly putty. The same concept as using clay but maybe easier to source. Plus the colors are cool
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Ah, Silly Putty -- a blast from the past. I remember flattening it over top newspaper articles and comic book strips, and peeling it back to see a reverse image. Good times! Thanks for the pointer.
 
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