Super-Simple Projects Cut-Above Hunting Customize a sharp handle for a super sharp .

By Tom Kreger

1 Every successful hunter Drop Point Knife Kit deserves a respectable knife The Sarge hunti ng knife kit for skinning, cutting tent includes: 1) a leather sheath; 2 line, slicing jerky, and for the 2) a steel tang that measures 3 3 countless other tasks that they 8 ⁄8" long with a 3 ⁄4" blade; may encounter in the great 3) aluminum assembly pins. 3 outdoors. To have one with an (I’ll only use two pins in the eye-grabbing handle that you constructi on process; that’s all that is needed for the scale alignment. fashioned in the shop–now Besides that, you need epoxy to weld the scales to the tang.) that’s special. Starting with this popular hunting knife kit, I’ll show you how to cut the personally rewarding. Besides the wooden scales that make up the the scales for a dazzling look. kit, all you’ll need is a small piece pins, and then shape and finish blade’s tang using epoxy and fast, easy on the wallet, and and a few basic and supplies. handle, bond them firmly to the In all, you’ll find the experience of scrap (I used figured maple) Opening photo: Larry Hamel-Lambert; Project photos: Sandy Andrews April/May 2014 woodcraftmagazine.com 67 Prep the materials Shape and apply it in place with a small clamp or 1 For safe handling, wrap the scales locking vise-grip pliers, centering the blade portion with a few 1 Decide which side of the the jaws between the holes on the layers of paper towel and scale blanks you want facing tang. Next, trace the tang’s outline electrical tape (Photo A to the outside. Mark one “left” on the wood (Photo B 1 Resaw and plane a 1 × 1 2 and the other “right.” Make sure (For spot-on alignment, drill 2 ). ). × 12" piece of hardwood into⁄ the inside faces of the blanks the holes in one scale blank 3 two 8"-thick strips. Crosscut as described in Step 3 before the matching ends of the strips Lay the tang on the inside outlining and drilling holes in ⁄ 2 1 at 4 2" for the scale blanks. faceare dead of a scale flat. Sandblank, if and needed. clamp 5 ⁄ Using a drill press and a 32" the3 remaining scale blank.) Figure 1: Knife Exploded View bit, drill through the scale blank,⁄ guiding off the two outside holes 1 ⁄8" 440C stainless steel tang in the tang (Photo C steady the tang and scale blank on a drilling block to ensure). (I like the to bit

the outlining/drilling sequence withenters the the remaining wood at 90°.) scale Repeat blank. 3 ⁄4 3 " blade 4 Scrollsaw or bandsaw the scales to shape, cutting just outside the lines ( 5 Photo D ⁄32 " hole When cutting the scales, use a notched pushstick to keep).

1 Strike a line 2" beyond the Scale 5 3 1 fingers out of harm’s way. ⁄8 × 1 × 4 ⁄2" pin hole that’s closest⁄ to the Aluminum pins blade on both scales. Using this line as a guide, round over the front ends of both scale blanks.

this area without marring the Because it’s difficult to sand through 400 grit sandpaper. blade,6 Clean finish-sand or scuff-sand this sectionthe handle portion of the tang to establish good bonding surfaces. Now, insert two pins in the holes drilled in one of the scales. Mix up a A B batch of epoxy, and coat the inside

C D

68 woodcraftmagazine.com April/May 2014 E F G face of one scale, working some onto the pins. Place the handle portion of the tang onto the pins and scale. Coat the inside face of the remaining scale, and add it to the knife handle assembly (Photo E small pair). ofNow C-clamps clamp (thePhoto aligned F scalesLet the flat epoxy to the cure tang overnight. with a ). H I Shape and finish 1 the scales and 2"-diameter sanding Saw off any protruding pin drum to sand the concave 1 ⁄ ofnot Tru-Oil to remove Gun theStock stain) Finish. and with the surrounding wood. (Photo H sealed6 Remove the handle the tape with and five coats 2material, Clamp andthe blade the end pins of the flush movingnooks in constantly the finger-grip to prevent area paper towel from the knife in a metalworking bench burning and). Keep gouging the drum the tang. blade. You’re done. n vise. (I used scrap pieces of 4 Finish-sand the scales through leather to protect the blade from 400 grit and then rub down the wood with #0000 steel wool. Finishing the Leather sander with an 80 grit disc, shape 5 Apply a stain and protective I stained the leather sheath with themarring.) knife handle Using a ( Photorandom-orbit G Eco-Flo All-in-One Stain and Finish, over the edges evenly all around apply Rustoleum Wood Stain Acorn Brown, #2605 from Tandy, until it feels right in the hand,). Round and Ultimate,clear finish. Wheat, (I used to amake Q-tip the to www.tandyleatherfactory.com. grain pop [Photo I 3 Reposition the knife, and #0000 steel wool to knock down then finish-sanduse a rotary through carving 220 grit. any raised grain (being].) I then careful used

Convenience-PLUS BUYING GUIDE About Our 1. Sarge Drop Point Knife Kit #844451 $20.99 Designer/Builder An avid hunter and 2. System Three T-88 Epoxy Syringe, 1.6 oz. #143148 $14.50 fisherman, Tom 3. Tru-Oil Gun Stock Finish, 8 oz. #142763 $16.50 Kreger of Lugoff,

Above items are available at Woodcraft stores, woodcraft.com or by calling (800) 225-1153. South Carolina, has been in the Prices subject to change without notice. knife-making business for 15 3. Tandy Eco-Flo All-in-One Stain & Finish, #2605-03 $8.99 years. He sells all of the 150 Acorn Brown, 4 oz. he makes in a year to Above item is available at Tandy Leather Factory, tandyleatherfactory.com or by calling (877) 532-8437. customers across the country. Price subject to change without notice.

Illustration: James Provost April/May 2014 woodcraftmagazine.com 69 FREE YEAR! 2 YEARS for $29.99!

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