Here's a bit of a WIP accounting of this project:
I've missed a few steps, but most of it is here.
Basic designs and materials:
Rough grinding the bevel:
120 grit finish
Second side. Almost there with the 36 grit belt:
The edge is taken right to the scribe lines:
Rough grinding the smaller blade:
both rough ground to 120 grit:
Hand sand to 180:
clay
Post heat treat
finish ground to 120
The large blade developed just a bit of sori when quenched:
I removed the full tang pieces
Clean up the shoulders with the file guide:
I forged out a piece of wrought for both hilt and sub-hilt:
Scale is removed with pH down:
Filing the tang slot:
Almost there:
Walnut slabs have been laminated with ebony and the tang traced onto both halves:
Dry fit looks fine. However, This is where I screwed up. I began shaping the handle piece between the hilts when I lost my grip and the grinder took a nice chunk out of one face. That made the handle material for both knives unusable if they were to match. So, I switched out the stabilized Royal Walnut supplied so generously by Mark at Burl Source, for some nicely figured natural American Black Walnut..... and built both handles again
Tobi just checking in:
I went down the road to the local garage and used their torch to bend the wrought pieces to shape. You'll notice I have now switched wood types:
Shaping the hardware:
Start shaping the handle:
Handle is rough shaped with a file finish:
Now the blade is hand sanded to 600 grit:
Ferric chloride etch
Final assembly. JB Weld for the hilt:
J-Flex epoxy for everything else
Precision tools at work.
The small knife receives the same basic treatment as the larger.
Sheath design. Not sure why, but I seem to draw sheaths backwards:
Leather has been cased, stamped and dyed:
The two walnut inlay pieces have been routed to shape and the edges cleaned up a bit:
The two pieces have been rough shaped and test fitted:
600 grit sanding with Tung oil. This will dry and be lightly sanded then three more thin coats of oil applied.
The ebony stud-to-be is cut from a small block, drilled and tapped, then rounded on the grinder:
Then chucked into my precision lathe for shaping.
Almost done:
I like it:
That's about all the good photos taken during this project.
Thank you for your interest.
-Peter