December Hunter Project

[BrokenolMarine]

Had a very busy day yesterday, two contractors on site for two big jobs. One replacing a drain line 150 feet long. Took an excavator to dig the trench. Rather then dig up the old line, we dug a parallel line and put in a new line. The second contractor was repairing a section of (old) water damaged subfloor and replacing the flooring. The damage was hidden by the seller prior to the sale and finally come to light. The floor had started to sag and we were in danger of falling through. Nice to be safe again.

After getting them started, I went out to the shop and mixed up some two part epoxy and added some black tint to the mix for this part of the project. About to set the bone accents against the blade guard, and since it's natural bone, I wanted any epoxy that might peek through to blend. I had tried to square up the bone and smooth it as best I could, but no matter what some might suggest, I am not a ro-ro-ro-bot.

21 tinted epoxy.jpg

Carefully, I got each piece aligned, and then slowly applied pressure with the can't twist Clamps. This things are awesome. I left the blank and bone to cure overnight and went in to monitor the work. They certainly didn't need my help, or advice. I left them to do the work, it's what we pay them for. I'm sure they appreciated me staying out of the way.

22 bone in clamps.jpg

[BrokenolMarine]

However, after the trench was dug and the new PVC pipe was all plumbed, Tina did get the tractor out and help put all the dirt back. She loves her tractor and the contractor didn't mind that part. He had stuff to do at HIS farm... horses to feed before dark and such.

[BrokenolMarine]

This morning, I was back at it. I took the blank out of the clamps, and then using the 1" vertical belt sander and the oscillating sander, I shaped the bone accents, PRIOR to moving on to mounting the scales. The knife will move to polishing together, but I wanted the bone shaped before I started to mount the scales. They look pretty good for now.


The right side accent...

23 right side.jpg

and the left...

24 left side.jpg

Still a lot more to do.

[Hatchdog]

Blank is looking good, less blanky…

Too bad about the home repair, nice you have “a guy” to help out.

[BrokenolMarine]

Had a long session in the shop this morning. First, I got the scales ready to drill. I lined the scale up on the blank, and placed a scrap piece of Carbon Fiber on the Birdseye side, to prevent blowout. When I was certain I had the scale where I wanted it, I used the Kant Twist Clamps to hold them in place and tightened them down.

25 prepped to drill.jpg

With the scrap on the back side against the birdseye, the bit coming out of the panel can't blow out the wood upon exit and ruin the panel. I have had this happen, and then you have to figure out how to salvage the panel or start over... not the place you want to be.

26 preventing blowout.jpg

After repeating the process with the second scale, I moved onto making the pins from the rod stock, and the lanyard pin from the hollow brass stock. This simply entailed cutting the rod stock to length, then rounding the ends, and polishing the stock until it slid smoothly thru the holes. I sanded the scales from 120 through 800 on the flat sides, to reduce the work load one they are on the blank, and rounded the face that contacts the accent bone.

27 scales and pins.jpg

Began the glue up by coating the one side, applying the panel, and pushing the pins through. Then coated the second side with glue and preparing to seat the second scale.

28 the glue up.jpg

Seating the second scale is critical. The holes have to be exactly vertical and the pins properly aligned. Early on, I had made minor errors, and found that the second scale cracked when trying to force the scales into place. This is why I take so much care in alignment during the drilling process, and check and double check each step. In this case, the scale dropped into place and a light pressure seated 'er. I applied even pressure along the scales with the Kant Twist clamps and an additional clamp from the collection. (Normally used for woodworking.) I will order another pair of Kant Twist... I have needed them for some time now.

29 in the clamps.jpg

Still more to do, but we are getting close to the end. We are moving to the shaping and final sanding phase. Soon we'll apply finish and be rewarded with that pop of color from the Birdseye.

[markiver54]

Looking forward to seeing the finished product.

[BrokenolMarine]

Looking forward to seeing the finished product.

I am looking forward to that as well. This has gone much slower than it should have, other priorities popping up. Inside and outside the house. We spent half a day taking down the bay window curtain rods, putting up new heavy duty double curtain rods, then hanging new insulated floor to ceiling drapes and the ruffled trim thingees at the top on the second rod. Big difference. Stopped that cold seeping thru the windows.

[markiver54]

It's hard to stay on course when there are many other pressing needs. I get side-tracked by lots of other little things when trying to stay focused on a project. I guess that makes it even more rewarding when it's complete.

[BrokenolMarine]

Hopefully, after breakfast, I'll be back at it this morning. Fueled by a couple cups of coffee, this is the best part. I love these last steps.

[Hatchdog]

Hopefully, after breakfast, I'll be back at it this morning. Fueled by a couple cups of coffee, this is the best part. I love these last steps.

May the force be with you. Ready to enjoy the finished product.

[BrokenolMarine]

I spent a couple hours in the shop this afternoon. First things first, got the knife, I can start calling it that now, out of the clamps.

30 out of the clamps.jpg

As you can see in the pic above, the pins and the scales are a bit (just a bit... lol) proud. Time to start shaping. The first step is to take the knife to the 1x30 belt sander with the firm back plate and sand the pins flush. Remembering to sand a bit, cool with a spray of water, sand a bit and cool. Repeat until the pins are flush on both sides. This is necessary because the knife has to lay flush on the oscillating sander to sand the scales flush to the knife blank to begin shaping. I changed the size of the sanding drums three times to maximize the efficiency of the process. Large drum for the long spine, medium for the belly of the knife and a small one to get inside that finger groove.

Then over to the 1 x 30 belt sander with NO back plate which lets the belt flex and move. This allows the belt to wrap a bit around the scales and shape the scales to the spine and round over the edges to conform to the hand. I have learned in the past to keep the knife moving. Stop, even for a second, and the belt will cut a groove in the scales, ruining the scale or forcing you to take too much off the scales making them too narrow.

Back to the oscillating sander to shape the edges of the belly of the knife and the finger groove. Just roll the edges. Then put the knife in the bench vise and tape the back of the 320 grit and 600 grit and cut thin strips. This last sanding technique is what I call Shoe Shine.

31 shoe shine sanding.jpg

I work my way through the belly and the spine until they are glass smooth to match the sides. Two hours gone, I'm done and it's looking pretty good. I might hit the metal portions to make them glisten tomorrow, but all that's left is applying the finish, and then waxing the knife. BUT, you get an idea what the finished knife will look like.

32 needs finish.jpg

Join me tomorrow to see the unveiling.

[Hatchdog]

I get puckered just reading about your sanding efforts. Knife is looking great and I love that Birdseye Maple and can’t wait to see it with a finish applied.

[BrokenolMarine]

Back out to the shop this morning after Coffee and Biscuits and Gravy. (Miss T is so good to me.)
I spent an hour or so polishing the brass pins and the exposed belly and spine portions of the liner and the blade blank. Wanted them to look good before I added the Golden Oak Watco Oil to the Maple to make the eyes pop. Once I was ready, it was time for the payoff for all the work... ready, set....

Pop!

Here is a view of the knife, a tour around the four sides..... Let's start on the left.... The "Eyes" of the Birdseye Maple are the most visible on this side of the knife.

33 left side.jpg

Then roll to the belly of the knife, the grain is beautiful here.

34 belly.jpg

Another roll and we are on the right. A little more plain than the left, but not ugly...

35 right side.jpg

Last but not least, the Spine of the knife. The red lining really accents the tooling on the metal of the spine. Not bad.
I dyed the epoxy silver before using it. I didn't pull it out of the tooling but left it in. This filled the holes I tooled into the knife. This way, if the knife is used hard, the gaps won't fill with "stuff" that might contaminate things. In the pic, I see a little piece of epoxy on the guard just off the bone accent that I missed. I'll catch that before I move forward. Sorry guys....

36 spine.jpg

I left the knife to air cure, allowing the Watco oil to soak in, and any residual to rise to the surface of the wood. I will lightly sand the surface with 1,000 grit paper and may retreat with Watco again if needed. If not, Wax on/Wax off, two or three coats... heating the wood a bit to drive the wax deep.

Almost done.

[Mags]

Beautiful!

[markiver54]

Looks GREAT!
I really like the spine!

[Hatchdog]

Outstanding, looks wonderful and that spine pops too with the liner you put in. Good idea on leaving the expoxy in, those of us who have gutted and skinner large game understand just what you mean when you say leaving junk in the knife.

I did a back and forth on the birdseye with and without the oil and yep, “pop” is the perfect word to describe the difference.

Sorry BOM, we just can’t un-see that microscopic bit of adhesive.

[BrokenolMarine]

Outstanding, looks wonderful and that spine pops too with the liner you put in. Good idea on leaving the expoxy in, those of us who have gutted and skinner large game understand just what you mean when you say leaving junk in the knife.

I did a back and forth on the birdseye with and without the oil and yep, “pop” is the perfect word to describe the difference.

Sorry BOM, we just can’t un-see that microscopic bit of adhesive.

I know... me either.
Like most craftsmen, I don't look at my finished projects and see all the beauty that others see, I see all the little things I wish I had done better and swear I will do them better on the next try.

[BrokenolMarine]

Out in the shop after coffee this morning and put the first coat of wax on and while it dried I did a bit of shop cleanup, vacuumed the benches and all like always after a long project. Then buffed 'er out. Applied the second coat of wax and headed in to let the second coat of wax dry really well before going back out to buff it out.

Using a cheap hair dryer my wife found for me at a second hand shop, I heat the wax in the can, heat the knife scales, then quickly apply the wax. It drives it into the wood a bit and the wax and the oil help protect the wood. (At least that's what they tell me.) If nothing else, it helps spread the wax easier. Pics coming after the second coat is buffed.

Then I'll make a sheath for the practice... and might fancy that up a bit to do the knife justice.

Watch this space.

[daytime dave]

That is looking FANTASTIC!

[BrokenolMarine]

Thanks Dave... thought you guys might like a peek, almost time to buff the second coat.
In the pic below you can see the can of British Bee's Wax, the cheapo Dryer Miss T found for me at Goodwill, and the knife drying on the Leather Cutting Table.

37 waxing the knife.jpg

I'll buff 'er out in an hour or so and we should be good to move on to the sheath. Haven't decided on the style yet. Crossdraw? Paddle? Straight drop strong side?