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from file to knife

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Thesquirrelslinger:
big ole mill files can be obtained from garage sales for $.10 a piece :)

I mean files big enough to make a machete- we are talking some monster 15-20" files, 3/8ths inch thick, and 2" wide... double bastard cut.
:)
they make GREAT knives

Trapper Rob:
Thanks for doing this Kevin.

KHalverson:
next installment.
I like to lay everything out and prepare to epoxy on the scales.



ok
my epoxy is mixed and I apply a thin layer in the front .
where we don't want epoxy squeezing out on the knife blade and get more generous around the pin holes.
I install all 3 pins making sure that there is epoxy in the holes.


I then install the scale on the knife.
I put exoxy on the 2nd scale the same as the 1st and make sure to fill the lightening holes on the blade


next step is to clamp it all together.
how if your scales lie flat like they should it don't take much pressure to hold everything together.
do not over tighten and squeeze all the epoxy out starving the joint.


we have a nice glue up and only a very small amout of glue on the front of the scales
it wont be a big deal to clean that up later.
now we give the knife at least 24 hours curing time.

Adam:
Cool! These are some great tips.  Thanks for posting this.

KHalverson:
now the epoxy has cured and I proceed to file the outside of the wood flush to the  tang.
 

 here we are flush all the way around.



next we profile the sides of the wood close to our desired handle shape using files and rasps.

 
here the handle is shaped close to my liking.


 now its time to start sanding the handle using the hickory slat and various grits of paper.


after sanding to a 150 or 220 grit I like to burnish the wood with a piece of brown paper bag.


now its time for some finish.
I like Danish oil.
apply following the directions on the can.


after the Danish oil has dried I follow it up with 4-6 very light coats of tru-oil.
again following the directions on the bottle.
after the tru oil has dried I follow up with a couple coats of  gunstock wax.


now its time to take off the tape and remove the residue.
after a little clean up we have a finished knife ready for leather.


that's about it folks!
I hope this encourages some of you to try this on your own.
Kevin

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