Pre bolstered we handles?

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Dec 27, 2013
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Hey guys, I was wondering if anyone might be interested in wa handles that come with a bolster already attached. I have nearly 1000 pounds of cocobolo and several hundred pounds of Blackwood, And I was thinking of cutting the coco into wa blanks and attaching a block of Blackwood as a bolster and selling the handle blocks like that.

Is that something that would interest anyone?
 
How would you attach them? Just glue, or mortise and tenon, or?
Would they be pre-drilled/slotted?
From a Japanese perspective, wa handles are often sold separately and blades can be removed and installed into other handles... but this gives that narrow tang/somewhat cosmetically imperfect fit at the steel/bolster joint. If you do it this way the separate handle has to be pretty strong without a blade though it, i.e. not just epoxy but mortise/tenon or other mechanical means of reinforcing the joint in addition to glue, particularly with woods such as coco and bw that are so oily they may adhere with less strength. The "Dabney dovetail" is a cool example although in that case I believe the bolster front is fit close to the specific blade.
From a western perspective, often our take is to make the wa handle monolithic with the blade- i.e. stays on there unless destroyed off. This gives a cosmetically perfect tang/bolster joint, and since the tang stays in there from start to finish, it is a suitable reinforcement for the bolster joint. To do this though, the main point of the bolster as in other types of handles is to serve as a cosmetic trim for the tang cavity. One drills and broaches the handle block so the tang fits in, but carefully slots the front of the bolster to a "guard" type tight slot. So, it really has to be fit to the specific knife, during the build process as a whole.

All this to say, from a western approach I don't think it makes much sense to try to glue the bolster on before fitting the handle to the tang. From an eastern approach, you can do that- but at that point you're pretty much in the "wa handle game" outright, and would be more or less making finished reinforced handles and selling those, as many do.

Another thing- I don't like to use natural woods, even blackwood or coco, as a bolster on a kitchen knife. Even stabilized woods and some types of synthetics will move a bit or shrink at times. With a bolster fit close around steel, the unyielding nature of the steel as well as the somewhat more prolonged exposure to moisture at this end of the handle can promote cracking if the bolster material shrinks even a little. I've seen some paper micarta such as paperstone shrink and crack here. G10 might be the most resilient, or quality micartas. I'll put a coco block or stab burl etc behind such a bolster, as the added epoxy in the joint makes things just a little more forgiving.
 
I agree with Salem. If done right, you will get a lot of sales. If done wrong, they are only so-so for knives.

You have to turn a tenon on the cocobolo and drill a matching socket in the blackwood. They need to be a reasonably good fit.

You have the choice of selling the two pieces turned and drilled, but unassembled, or assembled and pre-shaped. Unassembled will allow the user to drill out the cocobolo and slot the blackwood as needed before final assembly. It will also save you the steps of having to glue them together and sand down all sides. You can sell them for less this way. I would suggest using a plain rectangle shapes if doing it this way ( say 1"X3/4" and 1.25"X1")). The user will shape the handle to his preference of size and taper, and cut the octagonal corners as he wishes.

If you sell them assembled and cleaned up, I would suggest drilling a 1/4" or 3/8" starter tang hole.

It is all a factor of how much work you want to do and what price you want to ask.

Next time I am making some of these, I'll have to shoot some photos and do a short tutorial.
 
Ben, if you do it with say with a slotted oak dowel with the big round holes drilled in the pieces of the blank. with a little say 1/8 or 3/32 one going all the way though the front and little holes marked on the joint faces for registration pins, you would have a winner. Just make sure everything is lined up and square and let the customer do the gluing, opening up the tang slot, and final shaping.
 
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