Another rehandled SAK :)

[MattW]

Another attempt at rehandling a SAK, this time with provision for the tweezers and toothpick. Again, I've used hawthorn (which is a nice wood to work and seems to take an oiled finish quite nicely).
http://www.zen15400.zen.co.uk/mech2.jpg
http://www.zen15400.zen.co.uk/mech3.jpg
http://www.zen15400.zen.co.uk/mech4.jpg
http://www.zen15400.zen.co.uk/mech6.jpg
The scales aren't quite as fat as the spartan I did last time but I've still made them 'chunkier' than standard.
cheers
Matt

[MotorbikeMan]

Another nice job :biggthump how easy was it to do the toothpick and tweezers?

[MattW]

Another nice job :biggthump how easy was it to do the toothpick and tweezers?

Thanks mbm :)

The toothpick and tweezers weren't too bad - just careful work with needle files!

I cut the notch first using a very fine pull-saw and needle files, and then carefully formed the channel using a leatherman saw blade and files. (You can use the old plastic scales to mark out the notch).

Because I've left the scales fatter than standard, I had to cut a small chamfer at the leading edge of the notch so that your fingernail can get to the tweezer / pick.

cheers
Matt

[Edd-UK]

thats wonderfull, well done.

do you do the sanding when fitted or is every thing done before the scales are glued??

[MattW]

Thanks Edd :)
I try to get everything done before fitting the scales (the liners are aluminium and mark really easily and all the blades get in the way no matter what you do with them!).

I basically do things in this order (I'm not saying this is the right way, but it's what I do :) ):

Pick a suitable piece of wood (I sawed a block in half, intending to sort of 'bookmatch' the two scales, but it didn't quite work out!)
http://www.zen15400.zen.co.uk/proc1.jpg

Decide where you are going to cut your scales from and roughly mark round them (these are from my first knife, hence the different colour):
http://www.zen15400.zen.co.uk/proc2.jpg

To remove the scales insert a stanley knife blade between the scale and the liner and gently twist adjacent to the pivot (do this carefully, there's a good chance you may break the stanley knife blade if you 'over-twist') - eye protection would be a good idea!:
http://www.zen15400.zen.co.uk/proc12.jpg

When you've removed the scales from the knife, you can see the raised bushings which are used to locate the original plastic scales - I use these bushings to locate my wooden scales too.
http://www.zen15400.zen.co.uk/proc3.jpg

Cut your wooden scale roughly to shape
http://www.zen15400.zen.co.uk/proc4.jpg

Then flip the wooden scale over, sand it flat (on the side which will be against the liner) and press the knife into the wood (using both hands - I had to use one hand for the camera!)
http://www.zen15400.zen.co.uk/proc5.jpg

You should be left with three circular marks in the wood which show you where to drill your scale. Mark the centre of these.
http://www.zen15400.zen.co.uk/proc6.jpg

Drill your scale to a depth of about 1.5mm (I ground a spur and point drill so that it has a tiny spur and drills a flat bottomed hole)
http://www.zen15400.zen.co.uk/proc7.jpg

You should then be left with this (you'll also have to drill a small relief for the corkscrew pivot) :
http://www.zen15400.zen.co.uk/proc8.jpg

The knife should sit snug against the wooden scale
http://www.zen15400.zen.co.uk/proc9.jpg

Then taking a pencil sharpened to a chisel point, draw accurately around the knife liner.
http://www.zen15400.zen.co.uk/proc10.jpg

Having done this, take the wooden scale and cut / file as close to the line as you dare - at some point, you'll have to put the scale back on the knife and finish it off carefully (having taped up everything you can on the knife!). Once you have the scale accurately shaped to the profile of the liner, it's just a case of filing and sanding to the profile you want.
http://www.zen15400.zen.co.uk/proc11.jpg

I forgot to keep taking pics at this point, but you basically just repeat this for the other scale.

I leave cutting the notch for the corkscrew until the scale is fully shaped and at the last grit before finish sanding (makes sure the corners are nice and sharp). If I'm fitting the tweezers and pick, I cut their notches and channels at this point too.

I go down to 1200 grit wet and dry and finish with 0000 wire wool.

To glue the scales on, I use 5 minute epoxy, thickened with sanding dust (I have plenty!). I'm very sparing with it - it's vital to keep it clear of the tweezer / pick channels - but as the main fixing for the scales is the bushings, you don't need much.

I then finish with thinned danish oil.

All this is my personal method refined after doing just two knives - it is probably completely wrong and your mileage will almost certainly vary!

cheers
Matt

[MotorbikeMan]

Great tutorial :biggthump

[ZDP-189]

Yes, fantastic tutorial.

I'd like to make a few suggestions:

Having gone to the trouble of bookmarking your wood, I'd use the lovely insides as the outside of the scales, so they match. You'll need to thin the wood before drilling the holes, but it makes a big difference.

I'd really like to see pics of your cutting the tweezers channels. Next time you do that, why not snap a picture and append it to this thread.

Do you want me to move this to the tutorial archive?

[MattW]

Yes, fantastic tutorial.

I'd like to make a few suggestions:

Having gone to the trouble of bookmarking your wood, I'd use the lovely insides as the outside of the scales, so they match. You'll need to thin the wood before drilling the holes, but it makes a big difference.

I'd really like to see pics of your cutting the tweezers channels. Next time you do that, why not snap a picture and append it to this thread.

Do you want me to move this to the tutorial archive?

You're quite right Dan - I forgot and started shaping the wood on the wrong side :rolleyes: - ah well, you live and learn!

Feel free to move it to the tutorials archive if you think it's good enough - I don't profess that I know what I'm doing!

best
Matt

[Hepotec]

Does anyone know how this would work with a SAk with a locking blade?

[MattW]

Does anyone know how this would work with a SAk with a locking blade?
I should imagine it would work fine (if I recall, locking SAK's use liner locks?) - You'd just have to be careful not to glue the sprung part of the liner to the scale!
best
Matt

[mloc]

I should imagine it would work fine (if I recall, locking SAK's use liner locks?)
Matt

The knives that you have re-scaled look great keep up the good work

As for the locking sak's some have a button type lock recessed in to the red handle material it's just a case of milling out a square hole and enough room for the spring it's hard to describe, but if anyone wants i'll put i pic up tomorrow as i'm off to work in a min :yuck:

[MotorbikeMan]

Yes, fantastic tutorial.

I'd like to make a few suggestions:

Having gone to the trouble of bookmarking your wood, I'd use the lovely insides as the outside of the scales, so they match. You'll need to thin the wood before drilling the holes, but it makes a big difference.

I'd really like to see pics of your cutting the tweezers channels. Next time you do that, why not snap a picture and append it to this thread.

Do you want me to move this to the tutorial archive?
I think that's an excellant idea, in fact......
;)

[Edd-UK]

Matt thats great thanks

Great tutorial too

[Edgehog]

Nice work & a great tutorial cheers :D

[Dave Budd]

i must be pschic, I ripped the scales off an old sak of mine the other day with a mind to put something nicer on! i get the feeling that it will take me a while to get around to though!

[Tiffers]

I found myself stood in our local SAK stockist the other day considering buying one to do a bit of work on..........

I'm seriously tempted!

Tiffers

[scanker]

Well, after reading this and your other thread on rehandling SAKs, I decided to have a bash myself:

Before...
http://www.ecardiff.net/misc/sak1.jpg

And after...
http://www.ecardiff.net/misc/sak3.jpg

http://www.ecardiff.net/misc/sak2.jpg

The wood's black walnut, the method's just as you describe. :)

I'll have to have another bash soon, and see if I can work in toothpick and tweezers.

Thanks for the tutorial.

[manofthewood]

Inspired me to have a go, nice one fellas

[neill116]

I took the handles off my spartan last night and started shaping some wood....:D

[manofthewood]

One step ahead mate....:D

[Gurthang]

Thats a great idea I'd never thought of rehandling an SAK before, I might have to give it a go the plastic scales on mine are looking a bit worse for wear.

[Bogflogger]

This is a great idea! A nice way to personalise a SAK and not too complicated for woodwork beginners.