Wednesday, September 4, 2013



I had originally bought some book matched maple burl slabs to complete this knife, but in my latest shipment from knife supply I received some DymondWood composite "Cocobolo Macassar" slabs. A phenolic type of material. I will apply them to AD1 for trial.

 Size is on the label. These are 5 inches long, 1-1/2" x 5/16" thick. Which should work for most knife handles.
 I shaped the blade ends to match. This is done with the disc sander.
 Drill holes for the pins (1/8" for this design) and push some tapered strips of wood. Popsicle sticks, skewers whatever you have. I found it helpful to clamp one scale to the tang, drill, clamp the second scale and drill from the first scale through the tang through the second scale. Temporary pins hold everything together.
 Shape with sander, rasp, files etc.
Remove the steel and match the two slabs. Reinsert the wooden pins to keep them lined up.

The drill press with a 1" drum sander in the chuck works great. Be prepared for lots of orange, smelly dust.
The benefits of using a composite material for a handle is that water will have little impact the handle. Dishwasher safe just may be what is required. Real wood on the other hand, however beautiful, will need maintenance and probably shouldn't be submerged in water.

On the downsize, phenolic smells when you work it and this particular material leaves a very visible orange-red dust. Yes, mask up and have the dust extractor or shop vac running.

The handle is close to the shape I want. When it's all in place, I'll take the finer sandpapers to it followed by a buff on the cotton wheel.

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