Squaring up blocks of handle material

[Tyler.t76]

What tools or methods do you guys use to square up blocks of handle material efficiently?

 

[Crag the Brewer]

Efficiently....? I can't help you.
What kind of materials?

I have a porta-band. (not good enough)
tablesaw. (kinda putzy)
Last time, I spit the small logs with a large, thick knife.... Then let them dry.
Idk... I'm actually thinking of getting a portable electric hand planner and making a stand for it. Then using it like a jointer.

 

[Richard338]

Disc grinder. Once you have one side flat you can easily get all the other sides parallel, square, or whatever angle is desired.

 

[Tyler.t76]

Efficiently....? I can't help you.
What kind of materials?

I have a porta-band. (not good enough)
tablesaw. (kinda putzy)
Last time, I spit the small logs with a large, thick knife.... Then let them dry.
Idk... I'm actually thinking of getting a portable electric hand planner and making a stand for it. Then using it like a jointer.

Mostly stabilized wood, but also synthetics like micarta and g10.

 

[Fixall]

I use a 12" disc grinder with a table that has both and X and Y axis for the miter gauge, and a custom made miter gauge.

I'll get you a video tomorrow. I can square up blocks ridiculously fast with it.

If you're talking scales, I use a drum sander or surface grinder.

 

[Tyler.t76]

I use a 12" disc grinder with a table that has both and X and Y axis for the miter gauge, and a custom made miter gauge.

I'll get you a video tomorrow. I can square up blocks ridiculously fast with it.

If you're talking scales, I use a drum sander or surface grinder.

I would very much like to see the miter gauge, I have a WEN 12” disc sander I use, but the gauge is not very steady and that’s where my issue with it is. I can get it to work occasionally but it requires some awkward hand positions, and I lost a knuckle just a few days ago doing it, and that’s why I’m looking for a solution haha. Could you private message me some info on it?
EDIT: actually just now realizing who you are lol, I follow your page on instagram, I could message you there if you’d like.

 

[Sam Wilson]

Mill.

 

[Fixall]

Mill.

That’s actually how I was doing it…. But with the amount I’m doing in a day (100+) set up was taking way too long.

I’m kind of surprised there’s not a stock setup on the market like I’ll show tomorrow. I suppose there’s not a lot of demand for a machine to square up blocks in bulk though.

Same with a truly variable speed 4” belt sander. The closest there is a $1000 Jet 4” x 36” that only goes down to a minimum of ~900sfm. I’ve been tempted to drop $2k to have a full custom built.

 

[Sam Wilson]

Yeah, I don't do 100 at a time that's for sure. Once the end mill is in, I'd say it's about 3-4 minutes a block, if that. For a couple at a time it works great.

Sam

 

[DevinT]

I use a surface grinder with a belt.

Hoss

 

[Fixall]

I use a surface grinder with a belt.

Hoss

I really like these block/scale holders when I’m using the belt surface grinder (as opposed to double sided tape).

 

[C_Claycomb]

“Squaring up”. Depends if a block is going to be cut for scales or for a hidden tang.

For stabilized wood, I have a bandsaw for splitting the blocks into scales, but have used Japanese rip saws and tenon saws.

For flattening one face of a rough block, or the sawn face of a scale, belt grinder 60 grit belt on glass platen followed by quick hand sand with paper glued to glass or Corian plate. I can square another face to the first with the same tools, but with tool rest table on the grinder.

I have a Proxxon disk sander, but only 240 grit discs. Prefer this for squaring end faces on blocks when I am going to make a hidden tang, can use the belt and glass plate.

For making the block or scales parallel and equal thickness, I have started using a plunge router and spacers. Fast, efficient, easy, and 0.2mm variation in thickness over a scale without trying hard.

Don’t think I would try the router method on Micarta, but then that is usually flat enough to just need lapping on plate by hand.

Rare occasions when I need Micarta precision thickness, I have a SGA and use masking tape and double sided or superglue to mount to a steel carrier. Slow, fiddly and have to account for tape thickness in measuring.

 

[butcher_block]

saw gets them close but then i use a fly cutter in my mini mill

 

[Fixall]

Just posted a thread with my method.

 

[HSC ///]

mill sometimes, not always

 

[Fixall]

 

[mooniesdl3]

I really like these block/scale holders when I’m using the belt surface grinder (as opposed to double sided tape).

View attachment 2671466

Those look awesome to use with a surface grinder.

 

[Fixall]

Those look awesome to use with a surface grinder.

They’re particularly good at getting scales nice and flat. The only downside is that you can’t really grind scales thinner than about .28” - .30”. I’ve modified mine to allow me to flatten scales as thin as .20” and 6.5” long.

I’m in process of making of something that I think will work a little better for me, but won’t be selling it as it will be so inspired by tr maker. I’ve actually been in talks with them about improvements and want to see if they’d like to make the modified design. They’re a great company from my limited experience.

 

[Tyler.t76]

Thank you for the replies everyone, I’ve settled on just modifying my disc sander to a bit more reliable.
Although I will add this to my endless list of reasons that I should get a mill.