Knife Making & Repair #2: Groovin' n gluin'

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Blog entry by johngoes posted 01-01-2009 12:02 AM 2343 reads 1 time favorited 1 comment Add to Favorites Watch
« Part 1: Replacing a kitchen knife handle Part 2 of Knife Making & Repair series no next part

Today I concentrated on the knife handle repair. On the bandsaw I split the canarywood blank in half and saw a really nice bookmatched colored stripe figure inside. So I decided to flip my blank to have bookmatched handles.

I planed the sides smooth using the new benchtop small parts jig I built yesterday. Then I carefully traced the odd-shaped skinny tang on the inside face. I began to sweat bullets as I sat there and quailed at the thought of chopping that odd shape out of the handle while getting a perfectly smooth face. I decided to take another look at the rotten handle and saw that the groove ran straight through the handle and thereupon I had an epiphany! It was routed! So I whipped up a flat bottom routing bit and a couple of scrap passes later I had a perfect setup for the handle.

Router table set-up for blade handle groovin’.

Blank grooving

Another examination of the old handle showed that the blade shoulder was embedded in the handle most of the way. So I chiseled a slot for the shoulder to fit.

Shoulder fitting
Shoulder cut

And after admiring the fit a bit (and showing it off to my wife who responded with a bored, “uh huh”), I cut a piece of paper bag and glued the halves together sandwiched around the paper. First time to try this but I’ve seen Norm do it so hopefully I won’t have any problems splitting the halves later.

paper sandwich glue-up

paper glue-up

After a bit of drying I’ll trace the original handle shape over the new blank and bandsaw it to shape and rasp/sand it to rough shape.

So far so good!

-- Anybody can become a woodworker, but only a Craftsmen can hide his mistakes!

1 comment so far

View StevenAntonucci's profile


355 posts in 4547 days

#1 posted 01-02-2009 03:51 AM

I just read the first and second parts of your method of work, and I have always done it slightly different in order.

Once you have the handle split and inlaid, I would have drilled the recessed side for the pins or split nuts. Next, I would epoxy the two sides together to the knife. Finally, I would drill the final pin location and size through both sections of handle, using the hole on the one side to locate it. Setting the pins and final shaping is easy from here…

-- Steven

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