Dunkield Posted August 26, 2014 Report Share Posted August 26, 2014 Having bought of on Bewsher500 damascus blanks, I said I would do a step by step just to prove anyone can make one. I should add I have only ever made one knife from a kit before, never from a blank and the only power tools I have access to is a drill. So if you have power sanders and the like and fancy do one you could whip through this in no time. So here was the blank I chose, to me it looked the best one in the profile I wanted, it will be used on roe and muntjac so the blade can't be too deep. Next up was the wood, I went for 'thermo' curly birch, it looks nice, was cheap but the downside is it has quite an open grain Sliced in half to form the scales Some initial roughing out First mock up A bit later with all the bits required apart from glue. The tang and the scales are already roughed up here ready for gluing One thing I did wrong here was to use a metal drill bit to counter-bore the holes for the corby bolts, there is a specific tool for doing this, I would buy one next time. Anyway onto the gluing, the point of no return! The two bits of wood either side are also counter-bored and covered in cling film so it all comes apart after curing Luckily it all came out OK. Next to saw off the excess bolts and then start filing down the profile From then on it is just taking it down to the desired size and shape And pretty well all done, I need to get those scratches off the blade and I have rubbed some CCL oil and wax into the wood since this was taken so it actually looks better then this now I have to say despite the fact my fingers are killing me it's been a pretty satisfying build, I just need to knock up the sheath and get an edge on it - then its blood and guts time Quote Link to comment Share on other sites More sharing options...
hedd-wyn Posted August 26, 2014 Report Share Posted August 26, 2014 That is stunning Dunkie I'd be well pleased with that result well done Quote Link to comment Share on other sites More sharing options...
kent Posted August 26, 2014 Report Share Posted August 26, 2014 very nice not a big job for someone with all the tools and a well equipped workshop but with basic hand tools and a workmate a job very well done indeed Quote Link to comment Share on other sites More sharing options...
Scully Posted August 26, 2014 Report Share Posted August 26, 2014 Very nice. I'm a sucker for a nice knife. Quote Link to comment Share on other sites More sharing options...
FalconFN Posted August 26, 2014 Report Share Posted August 26, 2014 Excellent work, lovely looking knife. As you say, it's very satisfying to make a decent knife and even more so to use it. I found sheath making to be satisfying too but actually much harder than the knife. Quote Link to comment Share on other sites More sharing options...
CaptainBeaky Posted August 26, 2014 Report Share Posted August 26, 2014 Nice job Quote Link to comment Share on other sites More sharing options...
welsh1 Posted August 26, 2014 Report Share Posted August 26, 2014 I do like a bit of Damascus,nicely done Quote Link to comment Share on other sites More sharing options...
Dunkield Posted August 26, 2014 Author Report Share Posted August 26, 2014 I found sheath making to be satisfying too but actually much harder than the knife. I have the leather for the sheath but am just trying to find a plastic insert. I have bought one but none of the sites (of which there seem to be less and less) state the size which is a bit annoying. Anyway hopefully its big enough, I will get the pictures up when it is done. Quote Link to comment Share on other sites More sharing options...
silver pigeon69 Posted August 26, 2014 Report Share Posted August 26, 2014 A bit later with all the bits required apart from glue. The tang and the scales are already roughed up here ready for gluing One thing I did wrong here was to use a metal drill bit to counter-bore the holes for the corby bolts, there is a specific tool for doing this, I would buy one next time. very nice job why/how did you go wrong? Quote Link to comment Share on other sites More sharing options...
CaptainBeaky Posted August 27, 2014 Report Share Posted August 27, 2014 very nice job why/how did you go wrong? Corby bolts have a specific drill bit for each size, You drill the initial holes through the scales to match the holes in the tang, then counterbore with the Corby bit to fit the heads of the bolts into the tang. It's like a stepped bit, with a plain header, giving you a square bottom to your counterbore, giving the maximum contact between bolt head and scale. Quote Link to comment Share on other sites More sharing options...
johnphilip Posted August 27, 2014 Report Share Posted August 27, 2014 Lovely job for your first one. If you make another give me a shout and i will sort you out some old bog oak just you pay postage, have a look on ebay for some mosace pins they look great when fitted. If you have a pillar drill you can get some sander bits from axminster makes sanding a lot easy. Quote Link to comment Share on other sites More sharing options...
Dunkield Posted August 27, 2014 Author Report Share Posted August 27, 2014 Corby bolts have a specific drill bit for each size, You drill the initial holes through the scales to match the holes in the tang, then counterbore with the Corby bit to fit the heads of the bolts into the tang. It's like a stepped bit, with a plain header, giving you a square bottom to your counterbore, giving the maximum contact between bolt head and scale. Exactly. I had the right diameter bit but the correct bit is flat bottomed like this If you count down to picture number 10 and look to the right of the middle bolt you can see where the epoxy has filled the tear in the wood. It didn't matter in the end as I sanded down past that, but I was pretty annoyed with myself at the time for not buying the right tool. Quote Link to comment Share on other sites More sharing options...
Dunkield Posted August 27, 2014 Author Report Share Posted August 27, 2014 Lovely job for your first one. If you make another give me a shout and i will sort you out some old bog oak just you pay postage, have a look on ebay for some mosace pins they look great when fitted. If you have a pillar drill you can get some sander bits from axminster makes sanding a lot easy. Thank you , I don't have a pillar drill but my dad does, I would certainly make use of it for the next one. I have a chunk of lead wood knocking about I think that could be used too, obviously would be a bit on the weighty side though. Quote Link to comment Share on other sites More sharing options...
TriBsa Posted August 27, 2014 Report Share Posted August 27, 2014 Nice job and good right-up. Looks a good and handy size too. Funny thing is that when you eventually grow up (well for me anyway) in terms of knife ownership you realise that bigger is not always better. I blame the Jim Bowie TV series as a kid. Tom Quote Link to comment Share on other sites More sharing options...
Old farrier Posted August 27, 2014 Report Share Posted August 27, 2014 Very nice job Lot of time and effort in that knife All the best Of Quote Link to comment Share on other sites More sharing options...
Paddy Galore! Posted August 27, 2014 Report Share Posted August 27, 2014 nicely done, I have some zebrano that's waiting to go on a knife, just need a knife Quote Link to comment Share on other sites More sharing options...
Dave-UK Posted August 27, 2014 Report Share Posted August 27, 2014 Thats excellent, now i want to make one, i have plenty of hard wood, am thinking some madagascar ebony would look nice. May i ask when you got the blank and bits from? Quote Link to comment Share on other sites More sharing options...
Dunkield Posted August 27, 2014 Author Report Share Posted August 27, 2014 Yes of course, the blade was bough off this very forum here: http://forums.pigeonwatch.co.uk/forums/topic/289772-damascus-knife-blades/?hl=damascus The scales were from http://www.thebushcraftstore.co.uk/ mainly because I was working down the road from them one day and I wanted to choose the wood, they seem to be running their knife making stuff down though The bolts were from here http://www.english-handmade-knives.co.uk/ Quote Link to comment Share on other sites More sharing options...
Bewsher500 Posted August 27, 2014 Report Share Posted August 27, 2014 That looks great Love a bit of burr I have some buff horn for one Quote Link to comment Share on other sites More sharing options...
Dunkield Posted August 28, 2014 Author Report Share Posted August 28, 2014 The hardest part seems to be taking a decent photo, it actually looks way better than that in the flesh now the oil and wax have lifted the colour more. I will try and get a better one, when/if the sun comes out again. Quote Link to comment Share on other sites More sharing options...
silver pigeon69 Posted August 28, 2014 Report Share Posted August 28, 2014 Corby bolts have a specific drill bit for each size, You drill the initial holes through the scales to match the holes in the tang, then counterbore with the Corby bit to fit the heads of the bolts into the tang. It's like a stepped bit, with a plain header, giving you a square bottom to your counterbore, giving the maximum contact between bolt head and scale. Ah, Thank you. Quote Link to comment Share on other sites More sharing options...
silver pigeon69 Posted August 28, 2014 Report Share Posted August 28, 2014 If you count down to picture number 10 and look to the right of the middle bolt you can see where the epoxy has filled the tear in the wood. It didn't matter in the end as I sanded down past that, but I was pretty annoyed with myself at the time for not buying the right tool. Ok, i can see what you mean. Thanks. Quote Link to comment Share on other sites More sharing options...
Paul223 Posted August 28, 2014 Report Share Posted August 28, 2014 Very nice, well done Quote Link to comment Share on other sites More sharing options...
happypig Posted August 28, 2014 Report Share Posted August 28, 2014 I know this chap.... He can provide blanks in all sizes and even custom up to your spec.... http://www.dorsetwoodlandblades.co.uk Cheers Quote Link to comment Share on other sites More sharing options...
demonwolf444 Posted August 28, 2014 Report Share Posted August 28, 2014 Nice job, i fancy one. Can't swing it though as i don't use what i already have enough as it is. Quote Link to comment Share on other sites More sharing options...
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