CKCA 2012 Club Knife

[Charles Vestal]

When I started work on the 2012 Club Knives I thought a WIP thread would be a good idea, so I tried to take photos along the way. (Edit to add) This is not a real time WIP, the photos have been taken over the last few months.

Some of the close-up shots are a little fuzzy, but I think you can make out most of whats going on.

I hope you enjoy the show.


Here's the blades as they came from the Water-Jet.

http://www.fototime.com/7D2620718093E58/orig.jpg

Removing some of the meat off the tang, getting ready for tapering

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Now the tapering

http://www.fototime.com/4BD3F8F2EDB945F/standard.jpg

Go back and remove a little more from the center of the tang

http://www.fototime.com/7FA53D03D3A1CCC/standard.jpg

Back to the platen.

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True everything up on the disc.

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[Kevin Jones]

Wow, that's cool. Thanks

[Bruce Bump]

I like the WIP
Its exciting to see so many. Thats quite a big job to make this many at the same time I bet.

[Charles Vestal]

Thats quite a big job to make this many at the same time I bet.

Bruce,

It was a pretty daunting task to get them ready for heat treat. I was able to get 18 knives out of the sheet of steel so I have some extras in case something happens to one of the 15.

After heat treating I am working in batches of five so it's not to bad, but I think after I get 15 completed I will probably have my fill of boot knives for a while.




The water jet cut leaves a slight taper, we need to square this up before we go any further.

http://www.fototime.com/A7A23AE5C19CAA3/standard.jpg

Marking two grind lines for the top and bottom edge.

http://www.fototime.com/88E7EDEF687D124/standard.jpg

Marking the center grind line 0.500 from the bottom of the blade.

http://www.fototime.com/0D65D88561FB0FE/standard.jpg

Using a worn 60 grit belt, I grind a 45 deg. along the edge of the blade.

http://www.fototime.com/08D1775ADD8BF90/standard.jpg

http://www.fototime.com/71488789C548A8F/standard.jpg

Now I start grinding the blade bevels using a 3" contact wheel with a fresh
60 grit belt.

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[Kenneth Springer]

Charles,

Thanks for posting these pix! Looking forward to more pix once you start the "assembly line."

[Charles Vestal]

Now we are ready to work on fitting the guards.

First thing to do is square up the ears that the guard sets on.

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Round the top and bottom of the ricasso.

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I had the guards roughed out by the water jet, the slot is under sized.

http://www.fototime.com/A39E13967DEFC15/standard.jpg

Measure the thickness of the blade.

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Measure the width of the guard slot.

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So we need to take off a little more than 0.380" from the inside of the guard slot.

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This looks close.

http://www.fototime.com/4880C74C28AD0C0/standard.jpg

Guard slips right on.

http://www.fototime.com/262DE21BE3ADDBB/standard.jpg

[Charles Vestal]

All the guards installed.

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Cleaning up the front of the guards with the surface grinder.

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Cleaning up the ricasso.

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Drilling for the guard pin.

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Dressing the blade flats with 400 grit paper.

http://www.fototime.com/D9407C1E24BAD69/standard.jpg

Eighteen boot knives ready for heat treating, and a few others in the upper right corner.

http://www.fototime.com/0D59743F000E9AD/standard.jpg

[bill flynn]

Charles

very cool ! Thanks for doing this !

Bill

[Charles Vestal]

The knives were sent to Bos Heat Treating and came back at a hardness of 60-61 Rc.

Now this is one of the parts of the process that I got lazy about taking photos.

After the knives came back from heat treating, I fine tuned the grinds with a fresh 60 grit belt. Then went to a 400 grit belt to get the final grinds set up.

Then we start the polishing by using a "broke in" 400 grit cork belt and then moving to a "broke in" 600 grit cork belt, I use green chrome buffing compound on the belts.

Here's where the photos start up again.

I have never had good luck going straight from the cork belts to the buffer (like Steve Johnson does it) so I hand sand the bevels with 2000 and 2500 grit paper.

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400 grit belt used on the top and bottom of the ricasso.

http://www.fototime.com/D1C7B85334BF102/standard.jpg

With the guard temporarily installed I rough out the guard profile with a 60 grit belt.

http://www.fototime.com/12525A409E7CA3C/standard.jpg

Grinding down the guard wings.

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Removing the bulk of the material from the guard cutouts.

http://www.fototime.com/16492EEC8F052AA/standard.jpg

Fine tuning the cutouts with the small wheel.

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Turned out just right.

http://www.fototime.com/A069E69679F2E78/standard.jpg

[Kevin Cross]

Thank you for posting this Charles. I am enjoying watching the progress.
Kevin

[Bruce Bump]

Its pretty awesome to see these come along Charles. Loving your equipment too.

[Charles Vestal]

Thank you to everyone who has commented.


We have to clean up the guard and ricasso before soldering. I use a piece of 4000 grit polishing paper, Fast Orange and Mean Green to prepare the surfaces.

Just use the polishing paper as you would sand paper and use the two cleaners as the lubricant.

http://www.fototime.com/C056213550897B0/standard.jpg

Using a nail set I swell out the top portion of the pin hole.

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Install the pin and peen

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Solder, flux, heat-gun, artist brush and a stainless rod, all the important tools for soldering the guards.

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Apply a little flux to the guard, ricasso juncture.

http://www.fototime.com/8D8AF3D557601A4/standard.jpg

Heating it all up.

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While applying the solder and holding the heat-gun I didn't have another hand to take a photo of apply the solder.

After the solder flows I use the stainless rod to work the solder around the joint.

http://www.fototime.com/E4B64B2FF25A55D/standard.jpg

Let the knife set in a mixture of water and a little TSP.

http://www.fototime.com/CF4DFAB7A9C9054/standard.jpg

In order to neutralize the flux we put the knives in boiling water with baking soda and dish washing liquid added.

http://www.fototime.com/D4743E0A7708EC1/standard.jpg

After the blades have cooked awhile we transfer the blades and the water mixture into an ultrasonic cleaner to continue the neutralizing process.

http://www.fototime.com/3A48B462B6F4D01/standard.jpg

[Barry Connell]

This is all very great.

[Charles Vestal]

Thanks Barry.


It's time to cleanup the solder joint.

These gravers are made out of nickle silver rod and the ends are ground at about 45 degrees.

http://www.fototime.com/84EA5E35C0454B7/standard.jpg

I use the gravers to remove some of the solder and to get the joint even all the way around.

http://www.fototime.com/C37D9466B03ABD7/standard.jpg

To smooth out the solder joint I use a small Cratex wheel held in a pair of Vise-Grips. Just rub back and forth until everything looks good.

http://www.fototime.com/43BB4DA5CED1E6A/standard.jpg

Using a piece of Micarta as a backer I clean up the face of the guard with wet dry paper, stepping through 400, 800 an 1000 grits.

http://www.fototime.com/EF391583A56BFDD/standard.jpg

When you peen the guard pins sometime you hit to close to the edge and this causes a dimple on the back of the guard. I pull the guard across a file to smooth out any of the dimples.

http://www.fototime.com/F79D538CDBF2A38/standard.jpg

http://www.fototime.com/39B13D871004EF8/standard.jpg

[Bob Betzner]

Charles, I usually don't follow WIP threads, but you've sure brought this one to life, and I've been thoroughly enjoying it. Thanks for all the extra work you're putting in to taking the images.

Best,

Bob

[Peter Elovich]

VERY cool indeed! The knives are looking great and you have a VERY nice shop and tools.

Peter

[Charles Vestal]

Thanks Bob and Peter.

We now move to handle installation.

First we need the scales flat.

http://www.fototime.com/2208DD4159233F6/standard.jpg

The table of the disc grinder is set at an angle that matches the angle of the tang taper and the end of the scales are dressed, This will be the end of the scales that will mate up to the guard.

http://www.fototime.com/3A3FE81075BD320/standard.jpg

Liners cut and ready to be installed.

http://www.fototime.com/7FC7EA65A5D906A/standard.jpg


Here's another section that I forgot to take any photos. The glue up.

You would think when working on five knives you could remember on one of them.

So we move on to drilling the the back scale for the thong tube using a 1/4" bit.

http://www.fototime.com/3E1458AC52B50D4/standard.jpg

Using a 15/64" bit we drill the through holes for the Corby bolts.

http://www.fototime.com/549C82F6BB29ECA/standard.jpg

Trim the handle material close to the tang.

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The second handle fit up and ready for the glue up, and again no photos.

http://www.fototime.com/539D695F4FDD6D4/standard.jpg

Drilling for the Corby's.

http://www.fototime.com/2FA26CD3AEA10C5/standard.jpg

Using a 6.50 mm bit we drill the thong tube hole.

http://www.fototime.com/E2A8CE6388230A4/standard.jpg

Trim the second handle scale.

http://www.fototime.com/77271236D70CAD9/standard.jpg

[bill flynn]

This all great stuff Charles.....recognized those scales on the second one even before I saw my name in that last pic :p

Thank you for taking the time to do this WIP

Bill

[Kenneth Springer]

Thanks Bob and Peter.

We now move to handle installation. . . . {pictures omitted}

Thanks, Charles.

You know, I must be losing it. Those first couple of pictures looked like desert ironwood to me, but by the last two pictures it looked like curly Koa.

Looking forward to the next installment.

[bill flynn]

nope, you are not crazy....that is in fact the case!

actually, Charles kinda explained it in the posts, but the pictures are so mesmerizing that it is easy to miss :D

I think we will be seeing some more pics before too long...

[Charles Vestal]

Ken, Bill is correct, I am working on five knives in this batch and I'm trying to get some photos of each of the knives worked in while we go.


Let's rough out the handles.

First a 60 grit belt to get a bunch of material quickly.

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Here's the rough profile.

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Drilling the countersinks for the Corby bolts.

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Ready to install the bolts.

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All glued up.

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Trimming the bolts close to flush with the scales.

http://www.fototime.com/3CE5F42F920239D/standard.jpg

Getting the bolts worked down flush.

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[Charles Vestal]

Using the rotary platen, we work through progressively finer grits, to refine the profiles and blend everything nicely.

http://www.fototime.com/8E3538835A8E610/standard.jpg

The hand sanding begins.

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All the handles ready for buffing.

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[Bob Betzner]

Love this WIP>

[Charles Vestal]

Thanks Bob.

Going over the handles with the buffer.

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The blades need a little shine also.

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[Kenneth Springer]

Great thread, Charles!

BTW, you have a lot of cool tools. http://www.customknifecollectorsassociation.com/vbulletin/images/icons/icon14.gif

[Kevin Jones]

Charles, just wanted to thank you again for your making the effort to document the creation of these first knives.

I know our members are going to be thrilled upon receiving these 2012 CKCA Club Knives.

For any of you who have never seen one, Charles's makes one heck of a Loveless style sheath.

[Charles Vestal]

Thanks Ken and Kevin.

Funny you should mention sheaths Kevin.

We now do a little leather work.


Making a pattern.

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Trace the templates on the leather, cut them out and end up with a bunch of parts.

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Glue on the keeper strap and stitch it on.

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Installing the welt and sheath front.

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Sanding everything smooth.

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Using an old Micron belt tuned over I wet the edges and burnish.

http://www.fototime.com/3223FF8974B9D38/standard.jpg

[Charles Vestal]

Wet forming the sheaths.

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Installing the keeper snaps.

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The finish is applied and the sheaths are ready to go.

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These four knives were along for the ride while the Club knives were being built. They didn't get any exposure until now.

Left to right 5" Chute, 4 1/2" Chute, 3/4 Boot and a New York Special

http://www.fototime.com/1C75FC1E735C71B/standard.jpg

[Charles Vestal]

OK, the knives have made a road trip up north and will be back soon.

They spent a little time with Coop and here's what Jim came up with.

Thanks Jim.

http://www.fototime.com/B93FB2A36395DBB/standard.jpg

[Bob Betzner]

Great lookin', Charles!

[Rick Sherwood]

Loving this thread superb work Charles. Can't wait to get a hold of mine when it's finished!!

[Doug Castor]

Fantastic work, Charles.
Great Coop image.

Doug

[Kevin Conkle]

Charles - Thank you for making these and the WIP. This is going a long way towards making up for my having to cancel my planned attendance at Blade this year.

I'd love to see your shop. I really like the catch box around the buffer, that's slick.

[Mark Farley]

Beautiful knives!
I was curious if you have made more.
Like everyone else I sure enjoy seeing the photos.

[Charles Vestal]

Beautiful knives!
I was curious if you have made more.
Like everyone else I sure enjoy seeing the photos.

Hi Mark,

The next five knives are in progress now.

Take care

Charles

[Kevin Jones]

Hi Mark,

The next five knives are in progress now.

Take care

Charles

Good, when do you think members can look forward to delivery?

[Charles Vestal]

Kevin,

I have the handles on the knives, but I had to set them aside while I get some knives ready for the Guild show.

I'm hoping to have them ready by early October and then get to work on the last five knives.

Take care

Charles

[Kevin Jones]

Good Charles!!!

[Bob Betzner]

For whom, may I ask, are these current five pieces being made, Charles? I was confused by the order of the first five, not sure why, can't remember.

Thanks,

Bob

[Charles Vestal]

Hello Bob,

The next five knives are for

Bob Betzner
Kevin Conkle
Joe Richardson
Jon Klein
Kevin Cross

The knives are being made in the order of post in Steven's thread, this seemed to be the best way to do it.http://customknifecollectorsassociation.com/vbulletin/showthread.php?t=1757

[Bob Betzner]

Thanks much, Charles. I tried to find a couple of lists but couldn't quite figure out (being the twit I've become) what the order was. Do appreciated it!

Best,

Bob