my new BK2 has arrived, making some custom cocobolo handles WIP

crimsonfalcon07

crimsonfalcon07

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Dec 27, 2010
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Made my first handle set about a month ago for the BK11. I figured since I got a BK2, it ought to have matching furniture. This is the third set of knife handles I've made, and it's definitely getting easier. Slipped a couple times on the sander as I was shaping it, so I got a bit of the coating off, but the shaping came off pretty well. I got the grooves for the pointer and pinky in and shaped the whole handle closely to the original handles, and it even still fits into the sheath quite nicely.

All work was done with a portable belt sander, sandpaper, a few files, a hand drill, some screwdrivers, and a hand saw, hence the lines that aren't quite straight.
I started out with a couple thin scraps of cocobolo wood. Then I cut them to a very rough shape, and did some basic 2D shaping with the belt sander. Then I drilled holes, using a clamp to hold the wood together, and one of the original handle scales as a template. I then used a knife I'm working on making, and a few sets of flat head screwdrivers to counter sink the hole, as the hand drill couldn't do big enough holes for the screw head and nut. I ended up getting slightly longer screws than stock, as the wood requires a bit more screw than the stock ones would allow.

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After counter sinking the holes, I wedged the nuts into one side, making sure that they were flat, and correctly oriented. Then I screwed the new screws (they're 10x32 screws, 3/4" long) in, and assembled the handle. Oh boy was it rough! I finished the 2D shaping with a coarse belt on the belt sander, which is where it got its coating nicked. Then it was time for some 3D shaping, so I swapped to a finer grit sandpaper. I used the roller on the belt sander to sand in the grooves and do the 3D shaping, and then rounded all the edges, using the original handle as a visual guide.

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I then switched to the 120 grit belt that was the finest I could find at Ace, and further refined my contouring. Once I was satisfied with the basic shape, it was time for the hand sand paper. I've done a bit of shaping with that so far, and am looking to fit the scales as closely to the tang as I can. The wood grain is really gorgeous; this cocobolo is really great stuff!

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And, happily, it still fits cleanly into the sheath with good retention:

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Pretty happy with how this has turned out so far. I'd love to see some other rehandling jobs besides the usual micarta ones.
 
Diggin' the cocobolo :thumbup: Good lookin' stuff.

Any plans for the blade ? Strip it against the dark wood would look sweet ... Kinda like this :D


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Then you'll need a matching firesteel too ;)

Serious, I always liked that cocobolo. Nice job.
 
Thanks for the kind words everyone! I got the shape more to my liking, and finished hand sanding so it's flush with the tang, and am in the process of lacquering the scales, and recoating the blade (I'm using some of the spray-on blackboard stuff, since that matches the finish pretty closely, and is durable stuff that doesn't come off very easily, at least, not on the low-use areas that I dinged up). Once I get it all finished up, I'll get some pictures of the 2 and the 11 together for you.

I think it speaks volumes to how easy handle scales actually are that I was able to do all this in 2 days thus far with nothing but hand tools and a relatively low power hand belt-sander. I grant you, it's the plug-in kind, but still. Even taking it fairly slow, this is still a pretty quick process. All the materials cost me around 10 dollars, and I have extra wood for other projects. Much cheaper than buying them!

I chose the cocobolo because it's got those dark streaks that really look good with a black blade. Plus, cocobolo is just such a pretty wood! So I probably won't strip it. I'm not that great at refinishing blades, lacking sand paper that goes beyond 600 grit.
 
Wood handles are great. Here's my matched set of teak on the 2 and the 9

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Been working on a set for the 14 too. Gotta' get back on it.

Maybe this thread will inspire me ... NAH !
 
Just take it slow and you'll be able to correct your mistakes. I definitely had some issues, but it turned out okay. As requested, here's the BK11 and BK2 in matching furniture.

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Still need to sand down the bolts to fit properly though.
 
I rehandled this Condor Hudson Bay knife back in dec. That's Bird's eye Maple


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This is my very first rehandle job, Black Walnut on a Ontario Rat 5.


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Some in process zebra wood scales I started months ago before I lost the motivation and the tools to finish.


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My goal was really to make them as much of a drop in set of scales as possible, and it took me the longest to figure out. I have a "How to" thread around here somewhere which is a tutorial I made when I felt like I had the basics down. The nut side looks just like the factory Grivory scales with the recessed nut set down into the handle. They screw and unscrew just like a factory set.
 
Wow, much more pro than me. I usually just leave the holes circular. I don't know that I'd want to try the hex cutting. I was referring to the handles on the first two, as it doesn't look like those are screws. I should probably get a few more power tools, but for right now, I'm able to do a reasonably good job with the belt sander and hand tools. Here's a handle for my Bark River Bravo Necker 2 that I whipped up this morning. Took me 2 hours. I was lazy and didn't drill my holes in a straight line. Love this cocobolo! It's a bit easier to work than the bloodwood also.

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Oh, my bad, thats just brass or copper pin stock driven through the holes and peened over. I also use an epoxy to glue the scales on. Mostly it just protects the metal under the scales as it won't provide any shear strength. I stayed real old school on them cause i didn't want to detract from the beauty of the wood, I kept the pins small. When you've done 15 or 20 of them it gets easier and you get a feel for the project. You can't expect top quality your 1st time out.
 
I wasn't going to take this non-Becker, but since ya'll are strayin' ... Add my ESEE 4 to the list of custom wood scales :D

Actually like the way this one came out best of all.


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