Rehandle the neander way

[Mike Davis]

John asked me to make a new handle for his knife because the original leather handle was slick, tapered and hard to grip in cold weather, especially with gloves. Such a nice blade deserves a handle that gives a sure grip.

The knife as it comes from Fallkniven.


You can see how the hand would slide right off the end of the handle. There's nothing here to hold onto.


I like the good solid heavy tang. Would be nice to have a few rivet holes, but I don't want to weaken it so I will place some pins along side the tang. With a good coating of epoxy it will be fine.


Here are the canvas micarta blocks cut and ready to scribe.


I draw the shape of the tang on both sides of each block and then scribe the lines with an awl so they can't rub off.

Some photos were lost in the camera. The inside of each slab has to be chiseled out to fit the tang. This could be done with a Dremel tool or a milling machine, but I wanted to show how this whole project could be done with non-electric hand tools. So, I did it with a wood chisel.



After the slabs are fitted to the tang they are epoxied to each other and the tang. I left it in the clamps for a few days since I only worked on the weekends.


I drilled holes for the pins and for the tubes that will hold a lanyard. You will notice that the sharp edge of the blade is now covered with yellow tape, this is to protect me as well as the knife.


The ends of the pins are peened or upset to spread the metal slightly and make a permanent attachment.


Now I'm ready to start shaping the handle. Again this could be done with a Dremel tool, grinder or belt sander. I used a large round rasp and several round and flat files. I was a little surprised at how quickly the rasp cut micarta. I had to be careful not to take off too much material.


This is akin to sculpting. I stopped often to hold the knife and see how it felt in my hand. I had my son try it too since his hands are closer to the size of John's.


More shaping and smoothing with a fine flat file and it is starting to look and feel pretty good.


This will provide a secure grip for cutting and chopping in wet or cold weather. Even with thick gloves it feels great.





A few more fine touches and some finishing and it will be ready.


I had to make something to ship the knife back to it's owner since it is now too long for the original box.







Think I should double box, just to be safe? :noclue:



All done and ready to ship

[Canuck]

Wow (again this morning), Mike!

You are a true artisan!!!! There is certainly more to fitting a new handle to a knife than I would have ever thought.

Thanks for sharing all of the details, too!!!

Wayne

[ChrisMathes]

Oh My Goodness! That is a GREAT pictorial! The knife and box turned out beautifully! I like the dovetails and the raised panel construction...very sharp

I have wanted to do something like this for quite some time, but have never known how to go about it! I will be trying this and will share my pictures.

thank you so much for the inspiration and know-how!!!!!!!!!!!!!!!

Chris

[jeff...]

Nice Mike - real nice even used a "hand" drill - cool...

[LeftyTom]

Fine work, Mike.

[skysharks]

Wow Mike. The handle is onr of beauty and craftsmanship.
But then you make a fantastic box to ship it in. Heck I wouldn't want to use for fear of getting it dirty.

[NZAPP1]

That is excellent Mike Really nice work on both pieces

[Gotcha6]

That's some fine (and serious) looking cutlery there. The box looks great too! A man needs one like that around just to cut watermelons in the summer!

[Gofor]

Beautiful job,

and timely post!! I was spending the day sharpening tools (saws, axes, etc) and realized I need to make a handle for one of my machetes. So, a question: what did you use for the pins (i.e cold roll drill rod, etc??)

Don't have any plans for a back scabbard for a machete and also one for a double bitted ax, do you? Getting through some of the brush in the woods would be easier if I could carry the tool (s) on my back.

Go

[Mike Davis]

Most of the time I use 1/8 inch brass rod from Lowe's hardware. But this knife is used to gut and butcher moose in Vermont, so stainless steel was used for the pins and the lanyard tubes.

I got the parts from McMaster-Carr in Atlanta.

I know a couple guys in England that do ax masks and one guy in Canada. But, probably my brother in law is the best I have ever seen. As for a pattern, most folks trace around the ax then add 1/2 inch or so. Same goes for the long knife. Now a shoulder harness is another matter altogether.

Let me see if I can find some links for you.

[Dutchman]

That was interesting. Nice work. Thanks for sharing the excellent pics.

[McRabbet]

Nice pictorial sequence of a master at work -- nice job, Mike.

[RandyJ]

Nice solution to the problem, Mike! That's better than NEW
Where do you get your micarta??? I have a machete that could use a new handle:-D.
Keep up the excellent work

[Mike Davis]

Texas knife supply has all kinds of micarta.

http://www.texasknife.com/vcom/index.php?cPath=587_826