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Vpetrell

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Jul 14, 2015
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I had this blade made (not yet a maker myself) for me a few days ago and am now stuck on what to do for a handle. I told the kid that I wanted to make the handle and sheath myself. It was cut for a hidden tang, but I'm only using hand tools and my apartment floor to finish the knife.

Any one have suggestions for a material for a handle? I was going to use antler, but not sure I want to go down that road just yet. Also, I would only be using files to shape anything.

If anyone close to Cincinnati can help that would be awesome too!

Thanks!

Vince

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The blade is about 3.5 and the tang is about 3.5inches also
 
If you have a drill and some patience you should be able to do a hidden tang. I think your main problem is going to be fitting your handle with that short, severe curve in the guard. Also the bottom side of the guard doesn't look very flat. A scagel style handle with leather may be your best bet with that uneven guard.
 
Thanks, I started drilling the wood last night. So far so good. Just will take time and patience like you say. The guard is a bit long so I may have to reprofile the shape a bit, but it does sit flush with the wood. (Picture doesn't show well)

Thanks for the advice.
 
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Here is the progress so far. Snug fit for the tang and re guard is almost fitted all the way. Now all that's left is to epoxy the tang in and pin it in the handle before shaping the handle by hand.....with files... Unless I find a faster way I'll be done next week!
 
They build the pyramids with nothing more than copper tools, so you can certainly turn out a primo knife with what you can get at the hardware store. It's all about patience.

Shaping the handle requires little more than a 4-sided rasp and a bunch of sand paper. Take your time and go through each step to completion. Shortcuts will show up in the end product, so don't take them.
 
Thanks VaughnT. I messed up when I was drilling the wood and it's now a bit off center. What other tools will make this easier than a rasp and sand paper? I'm not sure where to go from here for shaping the handle.

Thanks!
 
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Here is a picture for reference. What will be the best way to get this done right with now belt sander?
 
The angle of the block as it now exists doesn't matter. You need to draw straight lines from the guard to the end of the block and shape accordingly. You asked how to get this done with no belt sander. A angle grinder with flap sanders, from course grit to fine, will take off material faster than you can shake a stick. But, Vaughn's right, you can do this fairly easily with wood rasps. By the way, and I am sure you know this, it would be good to shape the guard a bit more.:)
 
David Stifle said:
The angle of the block as it now exists doesn't matter. You need to draw straight lines from the guard to the end of the block and shape accordingly. You asked how to get this done with no belt sander. A angle grinder with flap sanders, from course grit to fine, will take off material faster than you can shake a stick. But, Vaughn's right, you can do this fairly easily with wood rasps. By the way, and I am sure you know this, it would be good to shape the guard a bit more.:)
Click to expand...

Before you shape the guard outside, squeeze it shut and try to close up the gap, I see gap
 
There is gap, small, but easy enough to fix. You're problem is doing this in an apartment. Still...if you have a torch heat it up and use a ballpeen hammer to gently close the edges. Lay the guard on another piece of steel, and carefully peen around the slot. It will tighten. If you don't have a torch, even putting it on your stove will heat it up enough to hammer it tighter. You can either soldier it closed or use JD weld to seal it.
 
I may have to jb weld it together as it is already epoxied together. The gap isn't the biggest concern to me as I will use the knife. My biggest problem is lack of tools and knowledge of making a handle like this. But hey there's a first time for everything. Winging it next time is now out of the question but I hope this turns out great. To me the "mistakes" give it character. Is there's any negative consequences to having the gap there?
 
Vpetrell said:
I may have to jb weld it together as it is already epoxied together. The gap isn't the biggest concern to me as I will use the knife. My biggest problem is lack of tools and knowledge of making a handle like this. But hey there's a first time for everything. Winging it next time is now out of the question but I hope this turns out great. To me the "mistakes" give it character. Is there's any negative consequences to having the gap there?
Click to expand...

Only a reflection on workmanship to some extent, but if you JB weld it tight to keep water out, nothing of a practical nature. Still, you should be able to hammer it tighter as you can always re-glue it.
 
How easy is this to do to aluminum. The guard was cut different when I received the knife and I cut the end off and sorta reprofiled the shape some. Thanks for the advice. This is all new to me still
 
Vpetrell said:
How easy is this to do to aluminum. The guard was cut different when I received the knife and I cut the end off and sorta reprofiled the shape some. Thanks for the advice. This is all new to me still
Click to expand...

The guard is aluminum? Well, it should be very easy to shape, tighten down the slot, etc.
 
Ok good to know. I gave the blade smith choice to choose materials.

I'm hoping to accumulate some tools in the future to help with my new hobbies. I'll put some more pics up tomorrow when I get a chance to finish it up

Thanks again.
 
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Back to square one. Going to do it right this time and take my time and make a sweet hidden tang......hopefully
 
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