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Old September 12, 2015, 04:24 PM   #1
rcmodel
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Maybe I got one more knife left in me?

Sept. 6, 2015
I had to give up knife making about 10-12 years ago because my hands couldn't take it anymore.

But, I thought maybe I had one more left in me?

I had an old 7 1/2" Japan 440c Cyro quenched fighter blade blank in the Junque for 15 years.
Decided to go Coffin-Handle, with Ivory Micarta, and Ball-End guard.

Decided I maybe can make one last one for myself.
But this will be my last one, as my hands are already hurting!!

I got all winter, and can take it slow, instead of fighting it like a one armed paper hanger trying to fight wasps in the wall filling orders.

Made brass balls for the ball end guard today, then my lathe speed control box went up in smoke!!!

Dang Nab It!!!

I'd like to do a photo thing in NFW from start, to the the finished knife & leather..
But it will be huge, so stay tuned!!

The general layout:
Guard stock is 3/8"x3/4" brass stock.
Ball stock is 3/8" round brass rod.


a1 Last Knife 3.jpg


Like this one I made in 2002: I actually made three of them and sold them.
Should have kept one for myself!!


a1A Like this.jpg

rc
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Last edited by rcmodel; September 14, 2015 at 03:52 PM.
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Old September 12, 2015, 04:29 PM   #2
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Sept. 6, 2015

Making Balls:

a3 Making balls.jpg


General layout, even made myself an extra Ball!:

(Never know when you might Lose a Ball in the basement Workshop!!!)


a2 Layout.jpg


rc
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Last edited by rcmodel; September 16, 2015 at 01:30 AM.
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Old September 12, 2015, 04:33 PM   #3
rcmodel
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Sept. 7, 2014

Milling tang slot in guard:
a6 Milling tang slot.jpg


Sawing guard to shape:
a7 Sawing guard.jpg

rc
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Last edited by rcmodel; September 14, 2015 at 03:57 PM.
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Old September 12, 2015, 04:37 PM   #4
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Sept. 8, 2014

Shaping guard on drill press with drum sander:

a8 Shaping guard.jpg


Balls & guard rough shaped:

a9 Balls & guard.jpg

rc
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Last edited by rcmodel; September 14, 2015 at 03:59 PM.
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Old September 12, 2015, 04:40 PM   #5
rcmodel
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Sept. 8, 2015

Testing Nickle-Silver with inlay methods:

a14 Silver inlay test fit.jpg


Rough Silver-Soldered in place:

a15 Inlay testing.jpg

rc
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Last edited by rcmodel; September 14, 2015 at 04:02 PM.
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Old September 12, 2015, 04:42 PM   #6
rcmodel
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Marking & Milling scales for tang:

a10 Squaring scales.jpg

a12 Milling Scales.jpg


rc
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Last edited by rcmodel; September 14, 2015 at 04:03 PM.
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Old September 12, 2015, 04:45 PM   #7
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Sept. 11, 2015

Test fitting:
a16 guard inlay.jpg


Pin locations marked:
a17 laid out.jpg


rc
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Last edited by rcmodel; September 14, 2015 at 04:18 PM.
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Old September 12, 2015, 04:48 PM   #8
rcmodel
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Sept. 12, 2015

Silver brazing the balls on the guard.
Silver Solder is Jewelers 'Hard' which is 85% real Silver, and melts at 1,400 degrees.


a19 Silvering balls on.jpg


Done!
Crud is Flux that mostly falls off when quenched hot:


a20 Silvering balls on done.jpg


rc
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Last edited by rcmodel; September 15, 2015 at 03:32 AM.
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Old September 12, 2015, 04:51 PM   #9
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Sept, 12, 2015

Guard rough polished:
a21 Guard rough polished.jpg


Finished making Nickle Silver & brass Thong Hole Liners:
a22 Thong hole liners.jpg

That's all for now, but stay tuned!!

rc
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Last edited by rcmodel; September 14, 2015 at 04:23 PM.
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Old September 12, 2015, 05:30 PM   #10
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That is going to be a nice knife when you are done Rcmodel.
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Old September 12, 2015, 06:52 PM   #11
rcmodel
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Cutting scale pins:
23 cutting scale pins.JPG

Pins cut:
24 Pins cut.jpg

rc
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Last edited by hso; September 14, 2015 at 08:22 AM.
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Old September 12, 2015, 06:53 PM   #12
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Sept 12, 2015

Drilling holes:
2 pins, front and rear, keep the scales aligned while drilling the second scale to match.


25 Drilling holes.jpg

Pins in temporarily:

26 Pins in.jpg

rc
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Last edited by rcmodel; September 15, 2015 at 03:35 AM.
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Old September 12, 2015, 07:39 PM   #13
Shanghai McCoy
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DANG! That is looking good rc.
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Old September 12, 2015, 08:02 PM   #14
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Looking good! Is the pin material 1/8th" brass rod?
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Old September 12, 2015, 09:04 PM   #15
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A magnificent piece ! Really, the blade shape is excellent. 440c properly treated as right at the top for all around no hassle appearance . The handle will show well when finished on dressy occassions while still being usefull and rugged. Kudos to you.
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Old September 12, 2015, 09:34 PM   #16
rcmodel
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Quote:
Is the pin material 1/8th" brass rod?
Yes, 1/8" bronze welding rod scuffed up on a belt sander for better adhesive bond.

rc
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Old September 12, 2015, 09:57 PM   #17
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Sept 12, 2015

Ready to silver-solder guard/blade joint.
Using Stay-Bright low-temp (430 degree) silver solder.

Using a engine valve spring to keep tension on the guard without heat sinking all the heat into the vice.


27 Ready to weld guard.jpg

Going Hot!
28 Geting hot!.jpg



rc
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Last edited by rcmodel; September 13, 2015 at 12:59 PM.
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Old September 12, 2015, 09:59 PM   #18
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And Hotter on the back side!
29 getting hotter!.jpg

Photo out of order!
Hand rubbed the blade first with 400. 600, and 1500 paper & oil.
30 Hand rubbing blade.jpg

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Last edited by rcmodel; September 12, 2015 at 11:04 PM.
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Old September 12, 2015, 11:31 PM   #19
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RC - I feel gyped...

A bunch of the photos are not coming through.


Bad "settings" at my end?

I seem to be gettin' a little less than half and sometimes I'll get on in a post and not the other or two.


Todd.
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Old September 12, 2015, 11:33 PM   #20
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RC,

Thank you for sharing the build details! This shows so many members the effort that goes into building a knife after the blade is ground/forged. It ain't as simple as many think!
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Old September 12, 2015, 11:40 PM   #21
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Quote:
Originally Posted by hso View Post
RC,

Thank you for sharing the build details! This shows so many members the effort that goes into building a (QUALITY - HIGH ATTENTION) knife after the blade is ground/forged. It ain't as simple as many think!
Agreed with the above conditionals.

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Old September 13, 2015, 12:04 AM   #22
rcmodel
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Quote:
A bunch of the photos are not coming through
I don't know?
They are all working on my PC & iPad.

Anyone else have problems seeing them??

rc
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Old September 13, 2015, 12:39 AM   #23
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I see all the pics. Gotta say you do things right RC! I won't hand rub blades as (even though I'm at the tender age of 59) my hands could never take it. They sure look good though but I use my 9" disc sander.
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Old September 13, 2015, 12:49 AM   #24
rcmodel
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Well, I decided to put everything I got in my Bag of Tricks on this last knife.

Already made some mistakes I wish I hadn't!

Been a long time since I did some of this stuff!!

Gotta learn it all over again!


I would have had it done by now 15 years ago!!

Course it don't help having to stop and bring the wife back home in the middle of things! Drilling the pins this afternoon and the phone rang.

She slipped out of the house and made it 1/2 a block up the street before one of the neighbors called me and said she was heading off!

rc
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Last edited by rcmodel; September 14, 2015 at 11:00 PM.
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Old September 13, 2015, 01:07 AM   #25
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Well RC, I only clicked in the thread because it was yours, and I sure am glad I did. Nice work. And good for you taking good care of Mrs. RC. I still have a box of 40sw brass slowly but surely filling up that I intend to send your way.
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