Here is
the start. The blade is hand rubbed and I have
flattened the scales and glued the liners to the
wood.
Pins have been cut and the ends has been rounded.

The
blade is covered by masking tape. The "shoulders" are
also covered. On this one the tang is not tapered
but the following is no different than if it was.

The blade
is placed in the special made vise. Using this
vise insures that the midaxis of the tang is perpendicular
with the drill.

Now one
of the scales is attached with a vise grip leaving
plenty of material on the sides and in the front.

The vise
is taken to the drill press and the holes are drilled.
Note the wedges to avoid any flexing.

Now
here is something a bit unusual. I use pins that
are
4mm ( approx. 1/6"). The holes in the blade
are also 4mm but to avoid trouble when inserting
the pins I now drill the holes in the scales again
with a drill size 4.1mm (approx. 1/25" bigger).
Making the holes a bit bigger has made it a dream
to put the pins in. No more cracks! The reason
I don´t make the holes in the blade 4.1mm
is that I will loose precision. In the wood the
fit to the pin is very good with the 4.1 but in
steel it is very sloppy.
To drill the holes I remove the blade and turn it upside down with the scale
still on. Now I just use the holes made before to index the drill.

Now on
side is done. I make the profile of the tang for
easy spotting the right/left side. Note on the
scale not drilled an arrow is drawn. This is pointed
to the front and to the edge. I do this on both
before any drilling. That way the scales match
each other when the knife is done.

Now I take
the project to the bandsaw. One scale is attached
with two pins and excess material is removed. I
saw very close to the steel to avoid to much grinding
when glued up.

Here the
scales are cut to profile. Note the fronts are
not shaped yet.

With a
can of beans for guide the rounded front is drawn
on one scale. You can use what ever you feel like
but this one suits me.

The one
scale has been sawed to shape.

The two
scales are put together with two pins and the front
is sawed on the other scale following the first
saw cut. Then I countersink the holes from the
back and remove any burrs with a very sharp wood
chisel.

With the
scales put together again I grind an angle on the
front with my diskgrinder...sorry the pic disappeared.

Be very
careful not to grind into the liner and into the
other side.

Now I put
the scales still with the pins into my vise and
hand rub the fronts to final grit wanted on the
handle.

I use a
small piece of micarta or an eraser to back the
sandpaper.
Lightly
coat the front and the front ONLY with danish oil.
Do not get any on the liners.

Now I buff
the front to final finish.

On this
stage I use a rough and a fine compound especially
for wood.

The pins
are taken to the vise and small notches are filed
in the middle for better glue bond.

Now I mix
epoxy. I use a magazine with smooth pages for this
operation. I like it since I always get a new clean
surface to mix on. I put the knife together one
scale at a time with the pins. Then I put in the
lanyard tubing last. I fill it up with masking
tape to avoid it getting filled with epoxy.

I put a
clamp on it. I use vise grips but will change to
Kant-Twis very soon. Much better control on the
pressure. Note that the excess epoxy just flows
out. I wipe it of with a rag with alcohol. The
I put some more clamps on to avoid any gaps. And
finally wipe it with alcohol again.

Then it
is put aside in a vise to dry up.

And this
is me all dressed up.
