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TURKEY DINNER TUTORIAL- begins on post 247!
- Thread starter esnyx
- Start date
5K Qs
Gold Member
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Very cool!! I'm looking forward to seeing this all unfold; this is the GAW that keeps on giving!
- GT
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- Dec 7, 2013
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- 914
Just getting back to this, congrats to the winners. But the truth is we're all winners for having Evan around here.
Michael
Michael
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- May 7, 2011
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Looking forward to the updates 
Fausto
Fausto
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- Feb 10, 2014
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Leeeet's begin.
I am going to start this off with Yanutsil's knife, a single blade spear with all stainless hardware, end cap bolsters, ivory bone handles, a small shield, and an easy open notch.
The materials and templates:
I have sprayed my steel liner and bolster stock with blue dykem so that I can clearly mark where I want to cut. I then use an old liner from a disassembled 15 as a template for the new liners, and my bolster template is a scale from a boys knife with end caps glued to a liner.
I cut them out on my bandsaw:
Now that they are all cut out, I remove the burr with a large single cut file:
Now to drill some holes. Double sided tape is my friend when it comes to using templates and drilling through multiple liners.
Clamp to ensure a secure bond:
Using the original liner as a guide, I drill through that bugger. I use an aluminum square tube as a drill block for a couple of reasons. Drilling through the liner with the aluminum below it prevents the liner from doming and creating a large burr when I am trying to drill through it, as it provides pressure to the liner allowing the bit to cut the bur clean and not leave it hanging off. Another reason to use a drill block is to prevent the pressure of the drill press from bending the liner. It doesn't have to be aluminum, but I had some scraps of this stuff, so I decided to use it for this application. You don't want to use wood for this because the drill will still push the burr down into the softer wood.
At this point, I grind the liners to size to avoid having to haft off all of that metal down the road. I keep the liners taped together and use the original liner as a template for size. Lets go over to the grinders:
Watch out for any 4 legged tripping hazards!
Grind the liners down to size. I try to leave on as little excess as possible, so I have minimal hafting after assembly. Yes, that is a treadmill motor control, and yes, I do run my grinders off of treadmill motors. Laugh all you want, they still work!
Gettin' there!
I forgot to shave this morning.
Hafted down to size. Now to clean up with acetone and de-burr.
At this point, I use an worn 220 grit belt on my grinder to remove the burr and smooth out the liners. I use the flat platen for this task.
While I'm there, I also flatten the bolsters and square up the side that will be butting up against the bone scales.
To shape the bone to size, I use an old scale as a template and tape it to the bone scales with double sided tape. I cut as much excess off the top and bottom with the bandsaw to preserve my belts, and to reduce the bone dust in the air.
Square up the bone to ensure a snug fit between the bolsters.
Again, using an old liner as a template, drill the scale holes through both liners. I use broken drill bits as pins to hold everything in line during drilling.
De-burr and sand smooth.
With the scale holes drilled, I can now use the old bone scale as a template to scribe the lines where I want my bolsters. This is the first step in preparing for soldering. Before this, you may want to mark the liners to to prevent possible confusion.
I use a pencil here to prevent the solder from sticking to the liner, leaving it uneven for the bone scale.
Same goes for bolsters.
This is where I break for the day. Updates coming tomorrow!!
Special thanks to Philllll the camera man!
I am going to start this off with Yanutsil's knife, a single blade spear with all stainless hardware, end cap bolsters, ivory bone handles, a small shield, and an easy open notch.
The materials and templates:
I have sprayed my steel liner and bolster stock with blue dykem so that I can clearly mark where I want to cut. I then use an old liner from a disassembled 15 as a template for the new liners, and my bolster template is a scale from a boys knife with end caps glued to a liner.
I cut them out on my bandsaw:
Now that they are all cut out, I remove the burr with a large single cut file:
Now to drill some holes. Double sided tape is my friend when it comes to using templates and drilling through multiple liners.
Clamp to ensure a secure bond:
Using the original liner as a guide, I drill through that bugger. I use an aluminum square tube as a drill block for a couple of reasons. Drilling through the liner with the aluminum below it prevents the liner from doming and creating a large burr when I am trying to drill through it, as it provides pressure to the liner allowing the bit to cut the bur clean and not leave it hanging off. Another reason to use a drill block is to prevent the pressure of the drill press from bending the liner. It doesn't have to be aluminum, but I had some scraps of this stuff, so I decided to use it for this application. You don't want to use wood for this because the drill will still push the burr down into the softer wood.
At this point, I grind the liners to size to avoid having to haft off all of that metal down the road. I keep the liners taped together and use the original liner as a template for size. Lets go over to the grinders:
Watch out for any 4 legged tripping hazards!
Grind the liners down to size. I try to leave on as little excess as possible, so I have minimal hafting after assembly. Yes, that is a treadmill motor control, and yes, I do run my grinders off of treadmill motors. Laugh all you want, they still work!
Gettin' there!
I forgot to shave this morning.
Hafted down to size. Now to clean up with acetone and de-burr.
At this point, I use an worn 220 grit belt on my grinder to remove the burr and smooth out the liners. I use the flat platen for this task.
While I'm there, I also flatten the bolsters and square up the side that will be butting up against the bone scales.
To shape the bone to size, I use an old scale as a template and tape it to the bone scales with double sided tape. I cut as much excess off the top and bottom with the bandsaw to preserve my belts, and to reduce the bone dust in the air.
Square up the bone to ensure a snug fit between the bolsters.
Again, using an old liner as a template, drill the scale holes through both liners. I use broken drill bits as pins to hold everything in line during drilling.
De-burr and sand smooth.
With the scale holes drilled, I can now use the old bone scale as a template to scribe the lines where I want my bolsters. This is the first step in preparing for soldering. Before this, you may want to mark the liners to to prevent possible confusion.
I use a pencil here to prevent the solder from sticking to the liner, leaving it uneven for the bone scale.
Same goes for bolsters.
This is where I break for the day. Updates coming tomorrow!!
Special thanks to Philllll the camera man!
Awesome WIP so far, Evan. Thank you for continually taking the time to put these together.
screened porch
Basic Member
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- Feb 19, 2012
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- 19,335
No matter how many times I cut it, it's still too short!
You make it look easy.
You make it look easy.
- Joined
- May 14, 2011
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- 2,773
Great tutorial guys! I can appreciate all the work that goes into making it, not to mention the knife itself!
- Joined
- Dec 11, 2011
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- 2,618
Great WIP Evan. I think I saw a bullnose hanging around waiting it's turn!
paulhilborn
Gold Member
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- Mar 22, 2006
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- 14,484
I love this stuff!!! Way to go Evan and Phil...
5K Qs
Gold Member
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Great WIP, Evan (and Phil) :thumbup::thumbup: I've been teaching for over 40 years, and I think one of the things that makes a good teacher is being able to explain stuff so it makes sense, and even sometimes make something look easy. And that description fits what you guys are doing! I look at your post and say, "That all makes sense! If I had the equipment, I think I could actually do that." Of course, my head says, "Looks pretty easy." But my hands just won't cooperate at all! 
Really enjoy watching the guys who can do it, though! Thanks!
- GT
Really enjoy watching the guys who can do it, though! Thanks!- GT