Knife Scales from Kitchen Supplies?!

Knife Scales from Kitchen Supplies?!

Some time back, Peter used some resin cast ramen to fabricate knife scales for the first time.  You know, as one does.  Since that project, he has been wanting to revisit the process and see if he could improve upon it!

A viewer by the name of Carson recommended using something else that might be found in the home kitchen, some detergent-free scotchbrite cleaning pads!  After trimming the pads to size, they fit quite nicely into the knife scale molds.  Then Peter proceeded to provoke the maker spirits by exclaiming, “…that was incredibly simple…”  This would later come back to jinx him in the form of a carpet tape integrity failure, resulting in casting new replacement knife scales.

Next came time to dispense and combine 7 ounces of Total Boat High Performance Resin/Hardener.  The long working time of this resin allowed for some black pigment to be added.  After a lot of through mixing, there was a ton of the bubbles in the resin.  Typically, all of the trapped air bubbles could ruin a casting, but this is remedied by using a pressure pot.  Utilizing just the power of air pressure, the pot will squeeeeeeze all of the bubbles to a point at which they are too small to ever see.    Peter first places the mold into the pot then carefully pours the liquid resin into the mold.  It is important to allow the spongy pad to absorb much of the resin as you go.  After the resin is allowed time to cure while relaxing in the pressurized vessel, it is removed and the shaping process can now begin.

Using non-jinxed double sided carpet tape, Peter fixes the two blanks to one another. Attaching them to each other allows them to be shapened uniformly on a variety of power tools such as the belt sander, band saw, and drill press.  After tracing the outline of the knife onto the taped blanks, they are cut into the rough shape of the desired handle. Now using a bit more resin from before, Peter sandwiches the scales around the knife tang, and then drives metal pins through all of the parts to keep them properly aligned.  Using a variety of sanders and some Grinder Burr Bits on the drill press, the final handle shape is achieved.

Sanding.  Some people don’t like it.  It’s coarse, and rough, and irritating, and it gets everywhere.  Taking the time to do it and gradually progressing through all of the grits and finally micromesh will elevate this build to an entirely other level.

Who would have thought that the humble scouring pad would have resulted in such a strikingly beautiful handle?  The combination of the silver metal, black resin and blue fibrous notes are wonderful.  What material is next?

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Materials Used :
Scotch-Brite Pads:

Rubber Gloves:

Mixing Cups:

Mixing Sticks:

Knife Kit:

Knife Scale Mold:

Bandy Clamps:

Grinder Burr Bits:

Micro-Mesh Pads: