Here is a letter sent to me from Jochen (aqua from ckd). The process is pretty simple it sounds like. He made a knife with this as handle material and it looked great/ I haven't had the time or chance to do my own yet. Let me know if it works out for ya.
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Hi Metthew,
well, thats not twice as complicated as it sounds. Ive done this the same way like making Micarta. You just need the fibreglass, epoxy resin, hardener and colour. Im sorry, but I dont know where to buy this stuff in the US. I bought it at
www.r-g.de . (click on the Union jack and you get many good basic information about fibres, resins and stuff)
Then you cut the fibreglass in parts which are as big as the plate you like to produce. I used 163g/m² - fibreglass. It took 50 layers for producing a 0,33 thick plate.
To cut out all the parts, is really fuzzy work , because the fibres on the side just fall out of the fabric.
You also need a simple press. For pressing out the air bubbles sealed in the resin and to get the plate flat. A very simple press can be used; just take two wood boards drill 4 holes in every of them and put in long screws and counter screw.
Then you mix the resin and hardener and the colour if you want. Put the first fibreglass fabric part into the mixture. Then lie it onto the under part of the press, which should be covered by a plastic bag, which is large enough that you can fold it upside that no resin can flow out. Then take the next fabric part and lie it on top of the other and so one. Take a hardener which can be worked with for at least 40 minutes. Anything else would be to short.
When the last layer is put on, fold over the bag and place the top part of the press. Now you screw it down with little pressure until the difference between bottom and top is everywhere the same.
Of course you can use anything else for making handle material. Here:
www.knifestyle.net/project7-schraeg-hinten.jpg I laminated a handle with fabric of old Army pants as carrier material. This is much more easy!!
I hope I could help you and, that you understood what I meant. I dont do descriptions in English very often. Just tell if you have further questions or want to see some pictures
Best regards,
Jochen
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Hope it helps.
~Matthew