Woodcraft Magazine Download Operating instructions

Brand: Woodcraft Magazine

Model: Download

Type: Operating instructions

Woodcraft, 406 Airport Industrial Park Road, P.O. Box 1686, Parkersburg, WV 26102-1686

77C58

12/15/08

5" Serrated Steak Knife Kit

Warning

These blades come pre-sharpened and you must cover the blade

to protect yourself from being cut while working on the handles.

Tape the blade with several layers of heavy masking tape from

the tip all along the cutting edge.

Knife Handles

The knife handles or “scales” can be made from any quality hard-

wood. Hard, tight grained woods are easier to polish and resist

damage better than soft woods. You will need two pieces at least

3/16" thick x 1" wide x 5" long.

Determine the side of each scale that will face out and be seen.

Mark the opposite side which will face the tang (face in) portion

of the knife blade. Lay the tang of the blade on one of the handle

scales, on the side of the scale marked in the previous step, and

trace around the tang and pin holes. Trace the other scale in the

same manner.

Drill the pin holes previously marked in the handle blanks on the

drill press using a 1/8" brad point bit. Use a backer board under

the handle blank to prevent tear out on the underside.

Using a scroll saw, band saw, or coping saw cut the tang’s outline

from both scale blanks. Cut to the outside of the traced lines. Us-

ing 120 grit sandpaper lightly sand the sides of the scales which

will contact the tang.

The outside edges of the scales which will face the blade tip

must be shaped, sanded and polished at this time. After the

scales are glued to the knife tang you will not be able to sand

these areas without marring the tang and blade. Shape these

edges to suit your proﬁle, sand from 120 through 400 grit, and

polish using a bufﬁng wheel and red rouge polishing compound.

Only this small area on both scales needs to be shaped and

polished at this time.

Handle Pins

Cut three 1" long pins for each knife from 1/8" diameter brass

rod. To help prevent splitting the scales and to make installation

easier, slightly bevel one end of each pin on a sander or with a

ﬁne ﬁle. Because the forward hole on the knife blank is slightly

undersized you need to pre-size the pins for these holes. Drive

the one of the pins approximately half way through the front hole

in the blade, the tap it back out. Keep track of this pin so you can

be sure to identify it when you are assembling the knife.

Assembly

Clean the tang and the tang side of the scales with acetone. Tap

all three pins bevel down through one scale from the side that

will face out, making sure the pre-ﬁt pin from the last step is in

the front hole. Mix enough epoxy to evenly coat both sides of the

tang and pins. Position both scales on the knife blade blank and

tap the pins through all three parts starting with the forward pin.

Clamp the scales to the tang (do not over clamp) and clean off

any glue squeeze out using a rag and acetone. Allow the glue to

dry overnight.

Shaping the Handles

After the epoxy has thoroughly dried, remove the clamps and

begin contouring and shaping the handle. First ﬁle or sand the

brass pins ﬂush with a ﬁle or stationary belt sander. Be careful not

to cut into the scale. Files and rasps or sanding drums can be

used to rough in the handle shape, round over the edges and ﬁt

the scales to the outside of the tang. Final shaping and sand-

ing should be done by hand with sandpaper. Do not remove too

much material from the thickness, concentrate on contouring the

edges and matching the tang proﬁle.

Finish sanding starting at 220 grit and progressing through the

grits to 400. Polish the handle with a bufﬁng wheel and red rouge

polishing compound.

Product #149176

Woodcraft Magazine Download Operating instructions

Brand: Woodcraft Magazine

Model: Download

Type: Operating instructions

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Woodcraft Magazine Download Operating instructions

Woodcraft Magazine Download Operating instructions

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