Shaping Handles and then flaring tubes

Brian Avila

Brian Avila

Joined
Jan 2, 2011
Messages
1,286
I was asked to handle a knife and flare the tubing like this:

2_zps1b2745f3.jpg


How I do handles is epoxy the scales and blots and tubes on, and then shape to fit.

What I don't know how to do is shape the handles and still have the counter sunk holes so I can flare the tube.

Do you guys have any ideas on how to get the finished product to look like the above picture when it comes to the tubes being flared?

I have thought of trying to epoxy the scales on and have the tubes come out after epoxy is set and then shape the handles, then countersink the holes and then add the tubes and flare... but I don't know how to get the tubes out after the epoxy is set, (maybe waxing the tubes, but knowing my luck I will get them set permanently)

-Brian-
 
I add my tube during glue up and after handle holes are drilled and chamfered... then grind the tubes flat with the scales, flare the tubes then chamfer the perimeter of my scales.

It can be tricky as you don't want to grind into the scales. Finish the flats the blend in the handle chamfer and rounding.
 
Last edited:
Daniel it sounds like you have quite a good system, but I don't understand your explanation...can you break it down a little more, what comes after what?
Like, 1), 2), etc.
Just not clear on WHAT gets chamfered WHEN.

Thanks!
 
elementfe said:
Daniel it sounds like you have quite a good system, but I don't understand your explanation...can you break it down a little more, what comes after what?
Like, 1), 2), etc.
Thanks!
Click to expand...

Will do tomorrow! 13 hour day and I'm too tired to make sense! it's easy but I'm not explaining it very well.

You set the handle chamfer before anything else... flare after that.
 
I appreciate the help, get some rest, come back and make sense. :D :foot:

Got to poke fun of the guy on the wrong side of the mountains....

ThisThreadIsWorthless_zpsa8f4561e.jpg


-Brian-
 
Hey Daniel, I have been thinking about what you said. So I have a better idea of what you are doing. If I understand right, the flaring of the tubes is done while the handle scales are flat. How does that affect heavy contouring?

If you take a look at this photo, it has three spyderco mules that I have done. the ones on the right have heavy contouring at the butt end around the tube, the tube is not flat:

DF8CA087-5B9E-4B6B-A85A-48AA343BA5D0_zps3p1mzdmd.jpg


If I did what you are saying the tube would end up contoured and not flared like I have previously done.

So would that lead to waxing/greasing the tubes and then removing them, then countersinking and then flaring the handle after shaping?
 
I've gone through alot of trial and error and I think I've formulated a great method for flaring tubes on heavily contoured handles. Ill post a thread tomorrow or friday with an in depth, step by step process of how I do it.
 
KalEl said:
I've gone through alot of trial and error and I think I've formulated a great method for flaring tubes on heavily contoured handles. Ill post a thread tomorrow or friday with an in depth, step by step process of how I do it.
Click to expand...

Awesome!!! I saw a post by you some time ago and I emailed you this evening about it. I look forward to seeing it.
 
I responded to your email but it will make alot more sense with pictures im sure! Plus I can show the actual process
 
KalEl said:
I've gone through alot of trial and error and I think I've formulated a great method for flaring tubes on heavily contoured handles. Ill post a thread tomorrow or friday with an in depth, step by step process of how I do it.
Click to expand...

Awesome!!! I saw a post by you some time ago and I emailed you this evening about it. I look forward to seeing it.
 
You could glue up like normal, then slide the tubes back out after it's clamped but the epoxy is still wet. Shape the handle next day, countersink the handle holes, insert tubes with epoxy and flare them. I often epoxy and flare the thong tube into an already glued, pinned and shaped handle. Takes an extra day but hey, you work on more than one at a time, right?

Or, you could glue up with sacrificial plastic pins. Next day, shape handle, drill them out, chamfer holes, install tubes. If you make the plastic pins quite short they will be even easier to drill out.
 
Brian, don't change a thing. :D Those are looking outstanding!

Here's what I do...

1. Prep scales as usual - flatten bottoms for flatness and adhesion; finish the fronts
2. Drill holes in scales and chamfer the holes with a 82 degree countersink - I usually go about 1/8" deep and use 1/4" tube.
3. Glue up with tubes in place and let epoxy cure
4. Grind flats of scales flush with tube. I grind to at least 220 grit so the ends of the tubes are clean; any scratches will be enlarged because of flaring. For a clean look lightly countersink the tube ends with a chamfer bit.
5. Flare - take your time and alternate sides a few times
6. Grind scales flush with tang on perimeter
7. At this point you will have a blocky, square handle with flared tubes... carefully shape the rest of the handle being careful not to grind into the flared tube. A gap between the tube and scales will give you some room to round the scales completely. The depth of the initial countersink in the scales in step two determines the gap and amount of tube that is flared.

Tip - use thinner walled seamless tubing; I prefer .020-.030" thick walls when I use 1/4" tube.


Pics - sorry for the dark pics but these show a few variations with similar knives


This one was done with my usual method as described above





Flared, Ground past flush then tubes were countersunk with chamfer bit.






Flared and ground just flush. Finished with scotchbrite belt and sandpaper...

 
That makes sense. What I want is to have the handles contoured like above, but have a flares tube. So I can not flare the tube before I shape the handle otherwise I will end up grinding into the tube.

Got it.
 
A procedure I've used with pins and thong holes is to glue up one scale and drill pin and thong hole. Then glue and drill through first scale and tang through second scale. Shape your handle then insert tubes and flare.
 
William Schrade said:
A procedure I've used with pins and thong holes is to glue up one scale and drill pin and thong hole. Then glue and drill through first scale and tang through second scale. Shape your handle then insert tubes and flare.
Click to expand...

I actually have not thought of that before. Only problem I see is not having the fronts even.
 
Or, put it all together with some other solid pins and a drop of superglue. Do all your shaping. Knock out the sacrificial pins and bust the superglue loose. Chamfer your holes on your already-contoured handle. Then glue up the knife with your tube stock and epoxy. When it's cured, grind the tube down flush, then flare it.
 
You must log in or register to reply here.
Back
Top