Dagger Case

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Project by Jim Jakosh posted 12-05-2013 02:33 PM 3236 views 19 times favorited 60 comments Add to Favorites Watch

This is a case for the corian dagger I made earlier this year. It is mainly for protection. I milled out the pocket area to fit the outline of the dagger and then had to add some clearance to the lid to allow it to close all the way.
The hardest part was figuring out how I was going to drill in the hinge pin holes so they were blind and did not show on the outside of the case. The last 2 photos show what I came up with. It is a 3/8” diameter piece of aluminum with a 5/32 drill epoxied into one end and a 10-32 screw threaded into the other end. I laid this assembly on the cardboard piece which is clearance for the lid and then drove it with a cut off Bondhus allen wrench which has a ball end on it. It worked so slick. I may have uses for this in the future.

The holes in the bottom of the case are 1/4”deep and they are 1” deep in the lid part of the hinge. I added some tiny FH screws to limit the movement of the pins. There are 1/2” long brass pins that I put in the deep holes and then install the screw in one end. I install the lid and tip it so the one pin can drop into the hole in the case and then install the screw in that end so it can’t come out. Then I remove the other screw, tip the case the other way and the second pin falls into the hole in the case and then I re install the screw and they are both captured.

It is made from curly maple and finished with semi gloss lacquer.

Cheers, Jim

-- Jim Jakosh.....Practical Wood Products...........Learn something new every day!! Variety is the Spice of Life!!

60 comments so far

View Randy_ATX's profile


881 posts in 3218 days

#1 posted 12-05-2013 02:38 PM

Stunning, Jim! Both the wood and the craftsmanship.

-- Randy -- Austin, TX by way of Northwest (Woodville), OH

View MShort's profile


1798 posts in 4194 days

#2 posted 12-05-2013 02:47 PM

That is a beautiful case. Well done !!!!

-- Mike, Missouri --- “A positive life can not happen with a negative mind.” ---

View a1Jim's profile


118066 posts in 4353 days

#3 posted 12-05-2013 02:55 PM

Beautiful Box Jim and very creative approach to make the hinge work. I’ve never heard of a Bondhus allen wrench before,very cool.


View Cedar Furniture Lodge 's profile

Cedar Furniture Lodge

824 posts in 3048 days

#4 posted 12-05-2013 03:05 PM

Beautiful box, I just love the gain of that wood.

-- "The Cedar King"

View HuckD's profile


312 posts in 2490 days

#5 posted 12-05-2013 03:17 PM

That box is fantastic! Well done.

-- Visit my Youtube Channel:

View maplerock's profile


529 posts in 2576 days

#6 posted 12-05-2013 03:18 PM

Great craftsmanship! Very nice work. I need one of those flexible drill heads.

-- Jerry... making sawdust in the Knobs of Southern Indiana

View CFrye's profile (online now)


11008 posts in 2616 days

#7 posted 12-05-2013 03:19 PM

Jim that curly maple is, as Randy said, stunning! The hinge solution is great. The screw used in the aluminum tube is a ‘set screw’? and the ball end of the allen wrench is sufficient to drive the bit into maple? Thanks for sharing.

-- God bless, Candy

View Rustic's profile


3256 posts in 4372 days

#8 posted 12-05-2013 03:42 PM

nice Jim love curly maple

--, Rick Kruse, Grand Rapids, MI

View Pimzedd's profile


628 posts in 4919 days

#9 posted 12-05-2013 03:43 PM

Beautiful box. Love the drill solution. Very imaginative.

-- Bill - Mesquite, TX --- "Everything with a power cord eventually winds up in the trash.” John Sarge , timber framer and blacksmith instructor at Tillers International school

View shipwright's profile


8560 posts in 3574 days

#10 posted 12-05-2013 03:52 PM

This is a case for the corian dagger I made earlier this year. It is mainly for protection

The case or the dagger? :-)

Seriously though, beautiful little box and a clever drilling setup.

-- Paul M ..............the early bird may get the worm but it’s the second mouse that gets the cheese!

View HillbillyShooter's profile


5811 posts in 3068 days

#11 posted 12-05-2013 04:24 PM

Beautiful work!

-- John C. -- "Firearms are second only to the Constitution in importance; they are the peoples' liberty's teeth." George Washington

View wiz's profile


218 posts in 2798 days

#12 posted 12-05-2013 04:39 PM

Great piece, Jim!! Great use of an amazing piece of wood!


-- Gary "Wiz" Burns, Oregon,

View stefang's profile


17039 posts in 4110 days

#13 posted 12-05-2013 05:01 PM

Super nice knife case Jim and a brilliant solution for drilling the pin holes. You have quite a talent for both woodworking and problem solving.

-- Mike, an American living in Norway.

View luv2learn's profile


3065 posts in 3079 days

#14 posted 12-05-2013 05:25 PM

This is class craftsmanship Jim and a MacGyver type solution for the hinge. Thanks for sharing!!

-- Lee - Northern idaho~"If the women don't find you handsome, at least they ought to find you handy"~ Red Green

View JanKrompan1's profile


63 posts in 2602 days

#15 posted 12-05-2013 05:42 PM

This type of hinge that you designed is outstanding. I am going to use it.

-- Jan, Free State Province, South Africa

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