I setup a spiral bit in my router and setup the router table for about .055" - .06" in depth. Using a single piece of my stock cut to length, I routed a groove in both sides to accommodate each blade, then split each from the main stock.
I also drilled a 5/16" recess in each groove to accept a magnet, which will help keep the tip from sliding off the knife later.
I then separated each handle from the original stock and marked a center line down the middle.
I then ran each piece through the bandsaw and flipped the cut side to the outer side, which matched the grain pretty closely. I probably could have flattened the cut edge then routed the blade groove, but it probably wouldn't have looked much different.
I then chose a spot to cut the tip half of the handle loose from the body and did so on the table saw
Time for the glue up, I mixed a small amount of epoxy and glued in the magnets, let that cure, then very lightly coated the tip half of the handle. You can use wood glue on this half, just don't let much if any squeeze out into the cavity for where blade slides in, otherwise it's a bear to get cleaned out to slide the blade into it. It may be easier to wax the blade well, then glue up with the blade inserted to help keep squeeze-out from blocking the blade. The wax should help act as a release.
I missed pics of the gluing process since I had gloves on and didn't want to get my phone covered with epoxy. Lastly I filled the void for the blade with epoxy and the mating surfaces and clamped the two pieces of the handle together. After wiping off the squeeze-out I slide the tip half of the handle over the blade to align it with the two parts of the handle. From here I shaped the two pieces of the handle together on the sander mostly. I had planned on a more ergonomic handle, but my sander gave out part way through, so much of the shape was done with a round-over on the router table.
Here is before the finish is applied and everything sanded to 320 The finish was using Dave Hawksford's technique of using dark walnut stain, wiped down with alcohol, then finished with golden oak. I used a BLO finish with a paste wax over it. I did do some final honing before mailing it out to Ken, but may not be as sharp as some of you would do.
Last edited by Darren Wright; 06-28-2012 at 09:47 PM.
To a small child, the perfect granddad is unafraid of big dogs and fierce storms but absolutely terrified of the word “boo.” – Robert Brault