Repeatable Handle Jig

[jficke13]

I'm trying to make handles a bunch of steak knives (aprx. 50). I plan to use a commercially available blade and tang. I had planned to use a router table and a flush trim bit to clean up the rough scroll saw pass on the handle so I could make those 100 scales in a repeatable, accurate, and clean production.

I used doublestick tape to secure the tang to a piece of plywood to make a pattern using the flush trim bit. However, when I moved to use the plywood pattern on my handle material, I was getting serious tearout problems (walnut, using a Whiteside 5/8" spiral trim bit).

Does anyone here have any thoughts/suggestions/criticisms?

 

[Stacy E. Apelt - Bladesmith]

CNC would be the best way if you are trying to make handles that are basically plug and play.

By using a hand controlled jig, you will still get variations.

The more solid the wood and template are mounted, the smoother the cut. Use the pin holes as mounting points with socket screws and washers holding the work tight. That should eliminate a lot of the chatter that leads to tearout.

Try a different bit if needed, but I suspect you are taking away too much wood in the cut. The basic way to avoid poor cuts in any milling/shaping task is to take multiple cuts and passes that are small instead of one large cut. The last cuts can be with a very fine bit to reach the final dimensions.

After assembly, you will have to sand and finish the handles, anyway, so I would leave a little extra to sand away. This will take care of the tear out issue.