I haven't done the sheath yet, but I can add that on once I do.
1) Here is the design traced out onto the steel (Aldo's 1084 1/8" thick). I don't have a bandsaw so I have to drill holes and "connect the dots" with a hacksaw.
2) The rough profiling is done. There are a couple of spots that I didn't get with the hacksaw, but it was just easier to do with the grinder.
3) All of the profiling is done. After smoothing the profile up to 220g on the grinder, I sanded all of the parts of the profile that will be visible on the final knife by hand. I use a dremel to shape and sand the inside of tight curves, and sandpaper wrapped around a section of PVC pipe to sand the inside of gentle curves. I also added the jimping and choil. The hole at the very end of the handle is to finish the tsukamaki and the rest are for balance.
4) I ground the blade with my Grizzly 2x72" with 60g norton blaze belts.
5) I skipped a few steps, but here it is after HT and a soak in vinegar to get the fire scale off. I've started doing all of my hardening after dark, so those steps wouldn't have photographed well, anyway. I heat in a charcoal forge and quench in canola oil. Tempering is in a gas oven in my kitchen.
6) I skipped a few steps in here, too (I was excited to get the grinding done and I forgot). I did post HT grinding with 60g and then 220g blaze belts, then fine and very fine scotchbrite belts (this was actually my inaugural run of the very fine scotchbrite belt). This photo was taken on a piece of cardboard instead of my usual flagstone because I didn't want the finish to get scratched. I also did hand sanding on the profile up to 400 grit.
7) I traced the handle on a piece of 0.09" kydex and cut out the scales.
8) I glue and drill each scale one by one so I don't lose the hole.
9) Second scale being glued on but without the hole drilled yet.
10) I trim the excess kydex with a jeweler's saw. I only cut to about 2-3mm of the blade end of the scales so I don't nick the nice part of the steel with the sawblade. I trim the rest with a knife. I cleaned up the edges slightly with a file, but they don't have to be too nice since they'll be covered up later. Sorry that the picture's fuzzy; I was doing this part at night and I don't have lights inside for photos.
11) I apply yellow mustard with a q-tip and let it sit for most of an episode of "Parks and Recreation." I do it prior to the tsukamaki so I don't have to wash any mustard out of the paracord.
12) I was hoping for a little bit more coverage with the etch, but I'm still pleased with it.
13) I glue on both menuki (white fiberoptic) with superglue before I start the tsukamaki.
14) Starting the tsukamaki. Where the handle is narrowest, the paracord lies flat where it crosses so it doesn't get too fat. I do this for the first few wraps.
15) When the handle starts to widen out, I do a slightly different wrapping method. The bottom strand does a full twist, which creates a groove for the top strand to lie in.
16) The top strand lies flat in the groove. I put a drop of superglue under the paracord each time it goes around the side of the handle. This helps to secure it while I'm doing the wrapping (I learned this trick from watching videos of Pavel Bolf).
17) Progress shot (making up for all of the steps I didn't photograph while doing the blade).
18) At the end of the handle, the paracord is just pulled through the hole until the tang is completely covered. The paracord in the hole is glued with a hefty dose of superglue. (By the way, I learned this type of 'end knot' as well as the use of kydex scales under tsukamaki from MS Wally Hayes' katana video.)
19) The extra paracord is cut off and the end is melted with a lighter. It looks like crap right now with superglue everywhere, but this will be fine once I add the shellac.
20) Another progress shot. The tsukamaki is finished but I haven't sealed it yet.
21) Finished! I applied the shellac with a small paintbrush until it was almost completely saturated. I frequently saturate it completely, but I wanted to keep the handle slightly absorbent for extra grippiness.
I'm very pleased with the way this knife turned out. The grip is very comfortable and secure in my hand.
I haven't totally decided where this one's going to go yet, but I still have plenty of time.
- Chris