when you make a "skeletonized" knife...

[SkaerE]

how do you smooth down the edges of the holes drilled in the handle area? (they are quite sharp after drilling)

must be some tool to do this...

 

[misque]

Try countersinking them a bit before you heat treat the blade.

 

[Mike Hull]

Also, run a drill bit back through the holes, after breaking the corners with the countersink. They tend to swedge a metal ring into the holes, and can make the holes too tight for the pins.

 

[White Knight]

I've always used a selection of tapered rotary grinders. The kind you can chuck in a drill press. I buy em from Sears or most hardware/home improvement places. Usually located around the drill bits. They are made from what seems to be the same material as a grinding wheel. Makes a nice smooth round hole.

Good luck,
White Knight

 

[raker]

I have a tapered countersink bit that 45's the edges of the hole. I then put a wore out roung nosed rotary file in the table top drill. Next I will tear some small squares of sandpaper to put between the rotary file and the part. Just push the rotary file down on the sandpaper and it will spin and sand out the holes very nice. A reamer will clean up any metal that may have been left at the edges of the taper.
I have tried various ways including tearing small strips from the shop rolls of sandpaper and shoe shining them back and forth through the holes. That sucks and takes a long time because the strips don't last long enough.
I would assume that you could use a dowl rod or anything else that that you had rounded the end would work.

 

[Kevin Wilkins]

Drill the holes slightly undersize and use a reamer and plenty of cutting fluid to ge the the final size. The use countersinker for metal (not one for woodworking!!!) and countersink the holse, being careful to get each hole countersunk to the same level. If there are still any rough edges, use a bit of sandpaper and a rod as already suggested above. Take your time and use a proper drill vise or otherr safeguards to keep the blade from catching on the turning tool and cutting off your fingers. NEVER try to catch a tirning blade with your hand. Turn off the machine at once and get outta tha way until it stops!!!