Need help How to mill a skeleton balisong handle

Joined
Feb 19, 2003
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Is any of you guys here make balisong knives? I just purchased a vertical milling machine and my first project is to make a skeleton balisong handle from a solid square or round stainless steel bar.

I need a step by step instruction. How to taper the bar. How to make a canal?......What kind of cutters?....Other tools?...


:confused:
 
This is an advanced project for anyone. You should buy good end mills and use coolant to keep the stainless from work hardening. If the chips get hot it will damage the finish. Be sure the work is held solid in the vice to prevent chatter. Kurt vices are best but expensive. I dont know of a tutorial for that type of handle but you can tthink your way through it one step at a time. A DRO (digital read out) would sure be nice to ensure uniformity. All drilling of holes, slots and windows should be done while the block is still square and easy to clamp.

I am certainly no machinist but have taken 6 quarters of Pecision machine night class at the college. Check it out at your community college.

hope this helps somewhat anyway and welcome to shoptalk. stick around and share
 
Bruce makes a great knife but he never took any english classes!!! :rolleyes:

I would under no circumstance attempt such a project until you have mastered the machine. You will end up with a lot of scrap!

Are you going to use titanium?

Thats precision..............right bruce? :D
 
Where can I find a picture of this type knife? You probably know I like hunters so if its really wild don't bother.

Thanks; Roger
 
don't have an exact answer for your question, but if you post this in the balisong forum i'm sure you'll get some advice.
 
I don't have a mill and don't know how to use one (yet)
But from my own experience, I would say that you shouldn't make your first try out of stainless. Get aluminum instead. Its cheap, and should be much easier to work with. It won't be nearly as big a deal, should you screw up halfway through (or god forbid on that very last step ;) )It will still make a good handle, and you can get some experience with your mill before you start trying to machine tough stuff.
I really don't know anything about a mill, but I would guess that for a project like your looking at in terms of laying it out and what cuts to make when, it would help if your familiar with using a router on wood. There are lots of books, and probably websites showing how to use a router table set up, and some projects get very advanced. If you look at those, you might get a better idea of where to start, and exactly what you need to do with your mill.
Theres definitely some correlation between them cause my grandpa, who spent his whole life in a tool and die shop,has one router set vertically with the cutter down over a special work table he built and another set vertically with the cutter up on another table he built, along with a free hand router all in his woodworking shop now that he's retired. And he always goes on about how "I guess that'll have to do since I can't afford a bridgeport" :D
 
Balisong forum?? Wow, all these months that has turned into a year I never ventured outside the 'Shop Talk' forum!! Maybe I better check around this place better.

Roger :(
 
Not to be mean, but this question is like going to a pilots forum and saying, "I just bought an airplane, how do I fly to Alaska?" Well, first you need to learn how to fly an airplane... ;-)

Seriously, a milling machine is a potentially dangerous tool that can cripple you. THe project you're talking about would be something for an experienced machinist to attempt, not for a beginner. Start off learning the basics of machining, either from books, another trained person in your area or from a local college that offers adult education.
 
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