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Wooden Knife Handle and Sheath

by Mehmet Emre Batopu

The handle of an ordinary knife was broken. That was my starting pointI decided to use top of a old pinewood walking stick as main mid-handle part and use different wood strips in layers to create a laminated effect on the two ends of the handle. I also planned to use a coin as a layer in the middle for a brass shine effect.

STEP 1: These are the layers to be used cut in basic shape. Here you see 2 coins (1TL), but I eventually went with a single 50 cent (respect)..

STEP 2: I grinded off the edges of the knifes handle side to fit the future slots of the wooden layers and the coin.

STEP 3: I drilled and carved slots in all layers for a snug fit with the knife handle metal.

STEP 4: I stacked up the layers on the handle metal, based on my choice of wood color variation. I also decided to grind the tip of knife to give it a sharper look (see the black marking at the tip)

STEP 5: I decided to use a black plastic separator and a red cardboard separator layers at the two sides of the brass coin. On the right, this is the final configuration right before I applied a two component epoxy adhesive (404) to stick everything together.

STEP 6: I let the epoxy cure over night. This is the basic shape of the handle after rough sanding by my home-modified grinder& sander (see photo below).

STEP 7: Final shape of the handle after hand grinding with rounded file and sanding by sand paper.

STEP 8: I decided to use a piece parquet to make the sheath. The same genuine wooden top cover of the parquet is used to match the other side of the sheath. First the knifes shape is outlined and cut deep into the wood using a craft knife.

STEP 9: Then all the excess material is carved out using a small chisel until the desired depth. A wooden piece is installed to ensure the position of the knife right in the middle of the sheaths vertical axis at the entrance.

STEP 10: The knife in place in the sheath and the top cover in place before gluing.

My only electrical device: THE FAMOUS HOME-MODIFIED GRINDER-SANDER. Originally it was a fruit processor back in the times when I was a baby, 1975.. Now it can be used with all standard circular sand papers and grinding discs.

STEP 11: The sheath bonded with epoxy and clamped. On the right the epoxy has cured over night, the tip is cut in basic shape and 4 holes are drilled for future connection with the leather belt loop.

STEP 12: This is sheath after rough sanding. I decided to use a separator at the entrance of the sheath to make it look neater and to achieve a full contact closure. I used again epoxy to fix it place and plastic tape for overnight curing.

STEP 13: The making of the leather belt loop and the handles leather fastener with press stud.

STEP 14: My sewing kit. (awl, beeswax, etc.) And the leather paint and varnish application.

STEP 14: After the varnish dried, the belt loop is attached to the wooden sheath by sewing the rope into the holes drilled in the wood earlier. The press stud is also placed on the leather fastener strip.