Belt Sander -Coarse and medium belts
Buffer and Jackson 51 rouge ( or similar rouge)
Drill and drill bit to match pin size
Drum mandrel and sanding rings (optional)
Glue clamps
Fine sandpaper or shop roll strips
A small amount of acetone and a rag
Applicator stick to apply the epoxy

Making the Knife:

Step1: Tape the blade with the masking tape from the point where the scales will start to the tip. This is done to protect the blade and to keep you from getting cut. Decide which side of the Dymondwood scales (or other desired handle material) will face the tang of the knife and which side will face out. Rough sand the side of the scale that faces the tang. Sand and final polish the radius of the scales with the belt sander and the buffer. This is necessary because after you glue the scales on the knife tang, you will not be able to polish this area again safely.

Step 2: Take one of the scales and position the scale exactly where you want it on the tang of the blade and clamp it so that you may drill the pinholes using the blade as a template. Drill size should be the same size or slightly larger than the pin you’ll be using. You should be able to easily push the pin through the hole. You are going to glue a pin in the holes as opposed to hammering it in or peIning it. After you have drilled the first scale, match it to the other scale so that they align exactly. This is a very important step since you will be using the first scale as a template to drill the second scale.

Step 3: Position the scales on the knife. Place pins through the holes. Make sure everything fits together. Also make sure the pins extend through the hole and the scales and that they are flush with the outside surface of the scales or extend slightly beyond the surface. Make sure you have a small amount of acetone and a rag handy to clean with. Before mixing the glue, remove any labels from the blade tang surface and clean the tang with acetone. Clean the surface of the scales that are to be glued with acetone. Mix the epoxy. With the scales removed from the tang, take an applicator stick and apply the glue to the blade tang and the side of the scales that face the tang. Place scales on the tang of the blade where you want them to go and make sure the holes are aligned. Put glue on the pins and position them in the holes making sure they go all the way through. Clamp the scales to the tang. Clean off excessive glue using rag and acetone, especially at the radius of the scales. Let the glue set per instructions. We prefer to let it set up overnight.

Step 4: Remove clamps and begin contouring and shaping the handle using a coarse and medium belt on your sander. If available use the drum mandrel and sanding rings. You want the handle to feel good and fit your hand. Now you’re ready for fine sanding using fine sanding and shop roll strips. Finish to at least 220 grit.

Step 5: Finally, polish the scales using your buffer and rouge (We recommend Jackson 51.)
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