In two sessions in which I would have been able to hit a very HIGH note if I had eaten beans... yes, the pucker factor was high...

... I drilled the holes in the blade blank. I put the knife blank in the frame and locked it on the drill press table.
NOTE: I had learned that EACH carbide bit is
supposed to be spun at a different rpm.

They vary greatly. The 1/4" is 800, the 3/32 is 2400. Wow. That meant I had to dig out my owners manual and figure out how to change the rpm on the dang drill press. This is an old JET and I have always just run it where they set it. Never had an issue. Turns out it was SET at 800 at the factory.
31 carbide pucker factor.jpg
In an earlier post I mentioned the high cost of the carbide bits. $21 for the 3/32. The 1/4 carbide was double that at $42. I wanted to do this right. So, cut in increments and use oil to keep the bits cool. The 1/4" cut took a bit of time, (Pun intended) but came out clean. I set up carefully for the next pair of holes near the blade guard and started the cuts with the 3/32 bit. During the second hole, the bit snapped. No idea why, I'm no machinest, I'm a hacker and always have been. I do my best. Miss Tina's comment? "I told you to buy two or three."

Luckily, the two holes were done before the bit broke. Perhaps the table shifted.
32 new holes done.jpg
If you look at the annotated image below, you can see where the holes are and their purpose. The new 1/4" hole is the one in the center. The new 3/32 holes are the two at the blade guard. I also added the 1/8" anchor hole for the endcap. I'm adapt and overcome.
32a new holes done.jpg
The REAL pucker factor was clamping and drilling the endcaps so they could be mounted. Being small, there wasn't much surface area for clamping. I got them done and they are test fitted below. They have NOT been glued and mounted and the pins are NOT glued in place.
33 endcap test fit.jpg
Loads more to do, and plenty of chances to crash and burn. Today I'll have to drill the holes in the copper accents against the blade guards. Once those are drilled and test fitted, we can really start to move forward. Then the hand fitting will begin in earnest.
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