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Make a Damascus steel Knife Part 4

Here we make the finger guard and wooden handle for the knife.


A template for the guard

Next we make the brass finger guard. I start by making one out of foamboard so I can tinker with sizes and the feel of it.

Try the template

Looks about right. Let's make it out of brass.

File the brass guard

To cut the brass finger guard I first drilled a hole at the end of the slot. Then I cut out the slot with a hacksaw. And finished it off with a file.

Drill the handle

Next drill the handle holes according to the template.

I am drilling quarter inch holes because I will be using quarter inch brass rod stock.

The wood blank

I am going to make the handle out of a clear epoxy resin. But first I need a mold so I can cast the resin. And I do this by first making the handle pieces out of wood.The thickness here is about an inch and a half. That gives us a little bit of extra when we carve it down.

Trace the profile onto the wood

I first drilled out the holes in the whole block so they are an exact match to each other and to the knife. Then I cut that handle rightdown the middle, creating the two handle halves. Each is about 3/4 of an inch thick. At this point you could call these two wooden handle halves knife scales.

Bubinga Wood Knife Scale


Pin with dowels

Next assemble the handles to the blade and pin it all together with wooden dowels.

I am using wooden dowel because this is just a temporary assembly.

Rasp the handle

Secure it in a vise and use a rasp to shape the handle to what you want.

The handle is shaped

The handle looks good.

NextLet's Continue and make a copy of it in clear resin


The Complete Modern Blacksmith

A truly unusual and unique resource, this extremely hands-on book brings together three popular but long-out-of-print classics (THE MODERN BLACKSMITH; THE RECYCLING, USE, AND REPAIR OF TOOLS; and THE MAKING OF TOOLS) essential for anyone interested in the making, repair, maintenance, or arcana of tools. An essential volume in any serious craftperson's library, this book covers setting up a smithy (anvil, forge, hammer, tongs, and all), and manufacturing everything from stone-carving chisels to decorative wall hooks.



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