December Hunter Project

[BrokenolMarine]

I haven't been in the Shop for a while due to health and other projects around the farm, but I finally dragged myself out. I looked in the stock of knife blanks from Jantz, and had two of each of the Hunter, Tanto blanks, and a Bowie. I chose the Hunter. The bowie will likely get a stag build, and the Tanto I might do a stack.

I spent an hour or so going thru the drawer where I keep the wood I have pulled from my various sources I selected for scales, and after trying and rejecting a dozen or so: Cocobolo, Dark Walnut, two sets of bone (not wide enough) and some beautiful Cherry and Oak, (didn't want to waste the pattern on the short blank...) I chose Birdseye Maple and a bone accent piece with Nickel Silver pins. I also selected the dark red for the backing/accent panel.

01 putting hunter together.jpg

Next I went to work on the layout of the metal work for the spine of the knife. Sketching and rejecting a number of patterns, I think I'll go with the 1/8" rope pattern on this one. I haven't tried this one before. I could just buff the spine to a high shine and leave it, but working the metal of the spine pushes my skill level and gives the knife that little extra.

02 spine design layout.jpg

I exceeded my hour in the shop for this session, but I'll get back on it tomorrow, probably a couple sessions. Maybe three. If there are any of my pals on the forum that want to take the trip with me, I'll make this a build along, if not, I'll post the completed pic at the end. Watch this space either way.

[RetiredSeabee]

Looking forward to watching the project.

[BrokenolMarine]

Alright then, I'll take the time to post the process. If even ONE of you wants to watch, worth my time.
Thanks.

[Hatchdog]

Make that two, I always enjoying the process. So fun to watch a craftsman at work.

[daytime dave]

That's a nice looking knife blank. This will be a great project I'm sure.

[Mags]

I like watching these too.

[BrokenolMarine]

The temps plummeted overnight, and stayed bitter all day. Arthur came to visit so I didn't get out in the shop like I'd hoped to, my hands took the day off. I'll get out tomorrow, and back at it. I'll be working it... keep watching.

[Hatchdog]

Good that you listen to Arther even tho he brings bad news.

[markiver54]

Will be following Marine.

[BrokenolMarine]

Managed to get back out to the shop for a couple hours this morning, and started to set up the knife for the work on the spine on the blade blank. First, I cut two cardboard pads and put them around the blade, taping them in place. This protects the blade from the vise, and my cutty parts from the blade. Next, I clamped the blade in the vise and prepared to lay out the pattern for the treatment of the spine.

03 spine work.jpg

I applied the layout dye to the back of the spine and allowed it to dry. The layout dye is temporary, and comes off after use. It allows you to "lay out" your work in pencil to use as a guide.

04 dyed.jpg

I spent about forty five minutes on the layout. The first diagonal cuts to match my drawing did not make me happy. I removed the layout and started over, carefully re-dying the spine and taking my time to lay out another more open pattern. Then I made the initial reference cuts to guide the deeper cuts. The reference cuts help insure the files/bits don't skitter. That can be a real problem.

05 initial cuts.jpg

Once the reference cuts are all completed, you go back and make the cosmetic / shaping cuts, careful to avoid the dreaded skitter which can ruin all the careful planning. Slow and steady is the key here.

06 shaping cuts.jpg

My time in the shop for now was done. Lots more to do here, but time to stop for a bit. The removal of the dye called for denatured alcohol. I was out. Miss T needed some 1x2s for winterizing the run on her coop and I needed that DA. Time to make a run to Ace Hardware.

After I remove the dye in the morning, the polishing begins on the cuts made so far. 325, 600, 800 grit. I use a special sanding jig for that process, I wrap the sections cut from the sandpaper sheet around a pencil or dowel and sand away. I sand up through the grits until I get a nice smooth result. 1200 grit, 1500? Sometimes.....

Stay tuned.

[BrokenolMarine]

Back at it after breakfast this morning, and the DA worked slick in removing every evidence of the marking dye. I was able to get set up and get started polishing the backstrap enhancements rather quickly.

07 dye removed.jpg

Rather than hand polish as I used to do, I decided to use the dremel and a number of polishing tips that Miss T found for me online. They are felt tips in various shapes. To go with that, I had located and purchased six grades of buffing rouge for metal that range from highly aggressive (Black) to extra fine (Blue) Red is Medium.

I started with the black, jumped to red and finished off with a blank buffing tip, to get a final polish. I'm good for now. After the knife is finished, I might come back with the pencil tips I bought for PINS and polish the spine again. Here are two looks at the spine after the polish work.

08 polished.jpg

09 second view.jpg

Next up, I worked on the layout of the scales. I cut them full size for now, not sure I'm going to go with the bone accent. Miss T thinks that may be too dark. I made an earlier Hunter with full size Birdseye scales and it looked pretty good. I will look at the Turquoise I have left, Maybe a Turquoise accent.

I started cutting the scales and got a SHOCK at the bandsaw. About halfway thru the first cut, the bandsaw blade broke, SNAP!... That will get your attention. Luckily I had all the shields in place and nothing happened except the saw kept running and the blade suddenly stopped in the work. Boy Scout that I am I had two new blades still in the boxes, and just had to remove the broken blade and install and adjust the new blade. PITA. (I also had to check my shorts, but that's a different story. )

Got the two scales cut out and set aside, will get back at it tomorrow, and decide where to go from here. As my legion of fans know... ... most of my projects are a flexible work in progress.

10 scales rough cut.jpg

Watch this spot.... for more.

[markiver54]

I really like the looks of that spine.
Hope your shorts checked out ok.

[Hatchdog]

Good thinking on Miss Tina’s part switching from hand polishing to using a motor. Hope it helps your hands a bit.

I hear you on the bandsaw blade breaking. When I was still working building parts for Boeing we used very large bandsaws all over the factory. I’ve had the “pleasure” of a blade breaking while using the saw. Also, if a blade broke in another area of the factory we all heard it. Not fun.

Nice polishing work on the knife and detail cuts too.

[BrokenolMarine]

Went out this morning and began prep for the glue up of the two scales. The first step was to mark and cut the Carbon Fiber liners. Not a big task, lay the two scales on the sheet, mark the needed width, and then cut the panel on the bandsaw. The sheet sparks when you cut it. Yup, she's tough.

Next, gathered up all the stuff you need so it's all handy. When you mix the two part epoxy, you have about five to ten minutes to get the scales in position and clamped before it begins to set. Then the adhesion will be weakened if you are still moving the panels around still trying to get adjusted. The other option is to mix one panel, then the other. When I first started, and was always fumbling around, THAT was the method I used. One panel at a time. Gotten smoother now. BUT, I make sure everything is at hand. Wax Paper, clamps, mixing / spreading stick, table is prepped. Coffee on hand for the technician...

I tape a few strips of tape onto the table and mix on that. Then when I'm finished, you peel the tape and throw the unused glue in the trash, rolled up inside the gloves. No mess.

11 prepping for glue up.jpg

Next, prior to the glue up, you rough the underside of the scales, and the tops of the liner panels. This insures good adhesion. I use 150 grit sandpaper and just make sure the entire surface takes a good hit. The liner is cut oversized to make the alignment less critical. We'll dress that up prior to assembly and finalize it in shaping and poishing.

12 rough up.jpg

Now, now comes the fun part. On your mark, set, mix. You mix up the two part epoxy. You can use quick set (which I do) or the other various mixes. If you use the slow set, the panels will shift and move a lot easier while you assemble. I mix up the epoxy and spread a thin (ish) coat on the scale, then fit IT to the panel. I try to hit my target, the center of the panel so there is less mess. The less the scale moves, the less chance of squeeze out flowing over the sides and making a huge mess. The Center clamp holds the scale in place allowing the end clamps to apply MORE pressure, then tighten the center clamp. then final pressure on the end clamps.

13 glue and clamps.jpg

I allow at least double the time recommended on the manufacturer's label. Likely overnight. Once epoxy is involved, heat becomes an issue. If anything in the build generates heat, the epoxy can let go. WE avoid over generation of heat from this point on. Drilling, sanding, polishing, we always do these steps in short bursts and cool in water.

MUCH more to come....

[Hatchdog]

I think I enjoy reading your tricks for doing the work as much as the work itself. Nice to have all those years of experience to use plus it’s very clear you are a tenacious researcher.

Back in the day I did lots of glueing (we called it bonding) of airplane parts. Our process was to use a 1/2” belt sander to rough up both parts and then wipe with acetone and then wipe again with a dry cotton patch. (Similar to a 12 ga cleaning patch). We called it wipe on wipe off referring to the Karate Kid movie. Our adhesive required either a two hour cure in a 140 degree oven or 10 hours at room temp.

Your work with the knives takes me back to those days but I’ve never worked with steel, just composites.

[BrokenolMarine]

After coffee this morning, I was out in the shop for about two hours. First up was to take the scales out of the clamps. Using the wax paper means the scales didn't stick to the clamps or the leather IF There was any squeeze out. There wasn't, but just in case.

14 out of the clamps.jpg

As you can see, the liners were intentionally oversized to insure even if there was a bit of movement during clamping, we were still covered and the scales didn't slide off the liner. I have had this happen, and you have to start over. Now it's time to begin to rid the scales of the excess. First to the bandsaw for the rough trim.

15 rough trim.jpg

Slow and steady, you don't want to trim too close, a slip here, and you are starting over. I don't have any more of this Birdseye stock, at least this thin anyway. I'm not sure I have ANY at all. This is looking pretty good so far.

17 trimmed close.jpg

Now we move to the oscillating sander. We can sand right up to the scales.

16 oscillate.jpg

This lets us trim the liner even with the scales, which are still oversized in relation to the blanks, but we are looking good.

18 looks good.jpg

[BrokenolMarine]

After several test fittings and squaring up the ends of the scales, I decided I wanted to use the bone accents/spacers after all. I marked the bone and prepared to cut two matching spacers.

19 needs bone.jpg

I made the cut with the dremel and a diamond cutting wheel. The pucker factor was a bit high, I'll admit. They were VERY close in size, and a couple minutes with a 220 wet sandpaper matched them up. They look pretty good, and will look a lot better when they are polished to about 1500 grit.

20 That'll do pig.jpg

Lot's more to go, but I have hit my allotted time for the session. Maybe the afternoon, maybe not. In the 20s here, or at least the low thirties and the moisture is high. If it doesn't snow, it's missed a good chance.

[BrokenolMarine]

The maple is still oversized, it will all match up in the end. Unless I blow it, toss the whole lot, and start over.

[markiver54]

The maple is still oversized, it will all match up in the end. Unless I blow it, toss the whole lot, and start over.

But, I know you're not going to do that.
Look'n good Jim!

[Hatchdog]

The maple is still oversized, it will all match up in the end. Unless I blow it, toss the whole lot, and start over.

Unlikely!