What size drill bit and reamer for handle pin holes?

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Jan 30, 2017
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I want to start drilling super-awesome handle pin holes in my wooden scales, so I don't end up with an oval-shaped glue outline around the pin. Does anyone have tips on which drill bits and reamers to buy?

SIZE: Do I want a drill bit that is -1 (undersize), and Reamer the actual size of the pin? Or should the drill bit be actual size, and reamer that is +1? I know the wood can shrink a bit after drilling but I'm not sure if reamers do a better job of producing a hole of the correct size. And I guess I need to buy a range of incremental sizes since the actual size of pinstock varies.

LENGTH: Should I go Jobber or Machine length? Any reason not to get as short as possible, since it's only ever going to go through a pair of scales?

MATERIAL: These bits would only be used for scales (wood/micarta/G10) so I don't need any fancy super-hard drill bit. (??)
 
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I'll let some others answer about reamers, but will point out that sharp and properly ground bits are the most important part of a good hole. I have never reamed a hole in a wood handle. I use brad point bits for many holes in wood that need precision diameters. The rest of the time I use jobber length bits. If a bit is not drilling right, I replace it. I have a good drill bit sharpener, but rarely use it on a small size bit. Buy them in 10-packs and toss them in a "USED" box for non-precise holes and/or use them to align scales on the second and third holes.

Much of understanding why a hole gets oval is understanding how the bit cuts in wood. The cutting edges go through the grain in various directions. In each revolution they will cut: down the grain - across the grain - up the grain - across the grain. The cut will have more resistance on the cross-grain cuts and try to move the bit left or right as the edge bites it. If the bit is very sharp and running at the right speed, the left from one flute cancels te right from the other flute .... in theory. In reality, one direction will always have more resistance than the other. Since the drill bit is locked in a rigid drill press, the wood tries to move left and right. This can make the hole wider in the long-grain directions than the cross-grain direction, creating a non-round hole. The following things will help control that inherent problem.

Besides good quality sharp bits, technique is important.
Make sure the drill press table is trammed to be 90° to the bit. If not, you get an oval hole.

Short bits flex less than long ones. If you are drilling holes that are less than an inch deep, use jobber length bits.

Clamp the handle or scale flat against a backer block of hard wood or micarta. Obviously, the board needs to be flat and smooth. Both should be clamped firmly in a drilling jig or flat to the drill press table. A good drill press table vise is very helpful. All of these measures will help prevents tear-out on the exit from the back and also assures the grain doesn't try to move the wood about as the drill enters and cuts.

Pilot holes are wise if you are using twist bits, especially for larger holes.

Feed the bit at the right speed and pressure. Let it do its work, don't try and punch it through the wood. Small bits in most wood should run fast. Be aware that certain woods will clog the bits and need the bit run in-out-in-out constantly. Oily and dense woods like ebony, cocobolo, desert ironwood, ringed gidgee, lignum vitae, and other similar woods must be drilled carefully and slower, or they can literally blow the block of wood apart (especially on drilling deep holes for hidden tangs).

Leave enough wood thickness in your handle block or scales to sand down after drilling the holes. This removes the frayed fibers at the surface. The hole will be much cleaner a millimeter below the entry/exit point.

Pin stock diameter varies and rarely is exactly the stated size, so measure it before drilling the holes. It is good to stick with one supplier of pin stock and get a batch of it at a time to assure all pins will fit the same. A cheap HF plastic micrometer is very handy in the shop.

Taper the end of the pins so they don't catch as they go through and exit the handle when being installed. A perfect pin/hole fit up should be a snug fit that just requires a bit of a twist and push to pass through. If you have to use a hammer, it is too tight. If it slides through easily, it is too loose.
 
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I use screw machine bits wherever possible, but a task such as going through two handle scales and a tang is going to take a jobber length bit, of course. You end up with a whole rollaway drawer of different bits if you're at this long enough.
 
Screw machine (stub) bits are great in drilling metal tangs, but may be too short for some handle blocks or scale sets. At 1/8" they are about 3/4" shorter than jobber bits.
 
Size wise I settled on two a long time ago. #30s for 1/8" pins and F's for 1/4 lanyard tubes. I too prefer the screw length bits for the #30s. The F's are normal length. I've never had a problem with the screw length #30s not being long enough but then, I make smaller and thinner knives for the most part. Even on larger thicker handle materials I'm only drilling one side at a time if the knife has a bolster and most of mine do, so I have plenty of drill.

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All I use #30s and a F. Sure simplifies life.
 
Hi Stacy,

With all the fantastic posts that you generate and pearls of wisdom you share, perhaps that you should consider assembling them all together into a convenient pamphlet or booklet.

I am sure that it would sell like hotcakes.
 
My "books" have been in the works for well over 10 years. My retirement is supposed to allow me time to do the photography and final formatting. There will be several books. Most all the chapters and articles are ready for the books. Some will need updating. There will be videos of some processes, too. Perhaps WIP DVDs to accompany some of the books. These will be really useful for some tasks that are hard to describe, like Corby bolts.

1) "The Modern Knife Shop - Techniques for Knifemaking in the 21'st Century" (I think the title says it all)

2) "Modern Knifemaking - A Metallurgical Approach to Better Blades." (Practical methods of making quality knives and HT'ing for different levels of knifemakers. Something between "Git it hot and dunk it in water" and Larrin's charts.)

3) "Building the Classic Sgian Dubh" (Multiple build tutorials and info for making several styles of sgian dubh)

4) "Making Hunting and Fishing Knives" (Probably three builds of each type and other suggestions)

5) "Shop-Talk, an Old Knifemaker's Ramble Though Time and Procedures" (this may be an interview style book or video. Or maybe a vlog)

6) "Building Knife Shop Tools and Equipment" (This will be for the folks who can't afford all the luxuries some others have.)

7) " Tips and Tricks in Knifemaking" (This will have many articles I have put in Shop Talk and other places.

8) "Cooking for People Who Like Sharp Knives" (Some of my many recipes as well as kitchen knife tips and techniques and sharpening.
 
Put me down for a series - must be autographed first editions. :)

Good luck with the retirement thing, there are not enough hours in a day already.
 
I don't have a lot of funds for fancy equipment. I square everything up the best I can, make sure the speed and feed rates match the material I'm drilling through, and then I start with a smaller bit and work my way up to the final diameter when drilling through steel. I also use a spring loaded punch on my steel to mark my spots. So for example, when I start drilling my 1/4 inch pin holes I start with 1/8 then 3/16 and then the 1/4 inch bit. For drilling through wood (or synthetic) scales I use the following method: I epoxy my first scale and then use the hardened holes as guides for drilling the wood. Then I epoxy the other side and use the wooden holes as my guide. You just need to make sure your surfaces are flat and parallel and that you've shaped the ricasso side of the scales before "glue up." For peened pins I use a Harbor Freight t-handled reamer. It only puts a slight taper into the holes, enough to grab the wood after peening the pins. Lately I've been using Corby bolts. For those I slightly oversize the inner diameter holes and use a reamer that came with the kit for the outer diameter. I've had no problem with epoxy showing around the pins or bolts. Another trick I sometimes use for regular pins is I make sure the holes are a little undersized and then sand the pins to fit. I do this by putting the pin in my drill press chuck and sanding the pin, periodically checking the diameter with my calipers.
 
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For handle scales on fixed blades it is a good idea to undersize the holes by about .010" then ream to roughly .002" larger than your pin diameter. You want the pins to be pretty tight yet move freely for when you glue up.
 
My 3/16 pin holes in my scales are drilled with sharp 3/16 carbide drills and I use peck drilling. For the tang I go up to the next wire size which is size 12. It gives clearance for the pin in the steel.
 
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