Refinished knife handle, lessons learned

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Dec 9, 2003
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My girlfriend had a kitchen knife that had a completely rusted through handle but the knife was also stamped with the family name and it had a center layer as well as two softer outside layers so I figured it was worth something both sentimentally and price wise. So i told her I would take it home and put a new handle on it.
Well the handle was rusted beyond repair till a half inch to the blade. Not good for a stable handle, but I figured a way out and carved into the corian to add an extra place of support, and thats the handle on the rear. The original idea was a handle in the midle, kind of like an alaskan Ulu knife. Great idea right?
Not really, got two problems. 1. it wont chop through thick stuff in the center area DOH! 2. the middle handle made it hard/impossible to sharpen the middle section of the blade. (this was fixed by grinding down the thickness of the middle handle. I can sharpen it now but not to quite as accute as I want for a kitchen knife. It still shaves though.)
For whatever reason I didnt realize those two problems through all my planning untill it was too late... Unless someone can disolve epoxy easily?
Here is a picture
IMG_0003.JPG


My main concern now is that the blade is rusting fairly fast. When i got the knife it was partially black/brown, not exactly rust, but looked just like years of use or something. I dont know a lot of japanese kitchen knives that use coatings so not sure what it was. Anywho I decided to try polish it right up but now its rusting. I got it fairly mirrored, hand sanded all the way to 1200 grit then buffed with compound. You can sorta see the specs of rust in the picture.
Question is how do I stop the rust. Its a kitchen knife so I cant just keep it lubed up with household oil... Help would be greatly appreciated as I hate to get this far and then lose it to rust.
 
One solution is to boil the knife for awhile to loosen the epoxy and remove the corian.. Then silver braze some threaded rod (or whatever you choose to use) to the remaning tang and turn it into a hidden tang knife..
 
The rear handle is surprisingly adequate, almost comfortable, so ill leave it there i think.

The boiling does seem like a good idea... I would have two holes in the blade but.... eh.

Keith, you mean like kitchen oil?
Dry is kind of hard as Hawaii is a humid and salty environment...
 
If it is used in the kitchen I would use a vegetable oil of some sort. I do not know if one is better than another but I use pam spray on my iron pans. A little goes a long way.
 
One solution is to boil the knife for awhile to loosen the epoxy and remove the corian.. Then silver braze some threaded rod (or whatever you choose to use) to the remaning tang and turn it into a hidden tang knife..

Is it that easy? I only want to remove the front handle, not the back. Will there be residue, a lot to resand and polish etc?
Only major problem is that it would look ugly with 2 holes in the blade.
 
As far as the epoxy goes, boiling probably is the best way as rocketmann mentioned. You'll have only a surface bond on the steel, so it'll come away clean. Because the Corian is nonporous, the epoxy may stay attached to either it or the steel. If it's on the steel, you can scrape with a plastic scraper (putty knife) without hurting your sanded finish. Do this while the epoxy's still hot.

Interesting project.
 
Is it that easy? I only want to remove the front handle, not the back. Will there be residue, a lot to resand and polish etc?
Only major problem is that it would look ugly with 2 holes in the blade.

make more holes, continue your new "feature" :D

-Page
 
Dont spray PAM on it, it can cause pitting in the metal. PAM is notl good for metal and for the body.
 
As far as the epoxy goes, boiling probably is the best way as rocketmann mentioned. You'll have only a surface bond on the steel, so it'll come away clean. Because the Corian is nonporous, the epoxy may stay attached to either it or the steel. If it's on the steel, you can scrape with a plastic scraper (putty knife) without hurting your sanded finish. Do this while the epoxy's still hot.

Interesting project.

About how long in the water to disolve the epoxy?
 
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