THE KHUKRI PROJECT- 06-05-2012

marthandan · Post by **marthandan** » Sat May 26, 2012 6:48 pm

moin...weld a piece of mild steel to the tang. any metal fabrication shop will do it for you. its far easier and you get a stronger joint in the bargain.

Rajat · Post by **Rajat** » Sat May 26, 2012 7:18 pm

The Resinova fast and clear that you are using is just a fast setting clear epoxy not really suited for this application. The regular epoxies are better and stronger but not for what you are trying to do.

Ok, here is a suggestion since you simply have to use the brass around the tang

Get simple MS metal strips around 3-4 mm thick and 1/2" wide and cut these into small pieces the size of the width of the brass cutout. you will need 4 or 6 pieces of the MS strip.

Weld these strips ACROSS the rat tail tang in sets of two sandwiching the tang in between. I hope you get what I mean.

Now insert the brass cut out inside the sections you have made. Keep it in the exact position and drill holes through the strips on both sides and the brass in the middle. Take it out again, apply a slow setting epoxy and hammer in metal pins the size of the holes to lock the brass into place. The exoxy will hold everything together and prevent any shakiness.

You will have to cut in furrows / grooves in the handle to accommodate the raised cross strips but this will be easy comparatively and will give an interesting look to it.

Moin. · Post by **Moin.** » Sat May 26, 2012 8:32 pm

The Epoxy's set quite quite hard. I am satisfied, tried a bit of hammering, twisting and grinding on the bench grinder-Nothing. The things set. Shaved away a few mm from the handle on the bench grinder as it was quite thicker than the spine of the blade. Now have to file and finsih the brass shape, have a lanyard hole drilled, slabs on the handle and polish on the blade.

Moin. · Post by **Moin.** » Sat May 26, 2012 8:42 pm

Rajat wrote:The Resinova fast and clear that you are using is just a fast setting clear epoxy not really suited for this application. The regular epoxies are better and stronger but not for what you are trying to do.

Ok, here is a suggestion since you simply have to use the brass around the tang

Get simple MS metal strips around 3-4 mm thick and 1/2" wide and cut these into small pieces the size of the width of the brass cutout. you will need 4 or 6 pieces of the MS strip.

Weld these strips ACROSS the rat tail tang in sets of two sandwiching the tang in between. I hope you get what I mean.

Now insert the brass cut out inside the sections you have made. Keep it in the exact position and drill holes through the strips on both sides and the brass in the middle. Take it out again, apply a slow setting epoxy and hammer in metal pins the size of the holes to lock the brass into place. The exoxy will hold everything together and prevent any shakiness.

You will have to cut in furrows / grooves in the handle to accommodate the raised cross strips but this will be easy comparatively and will give an interesting look to it.

Thats a nice idea Rajat but very complicated to execute for me. But the idea of sandwiching MS plates on the brass and running pins through can still be done. Ruling out welding but I guess the pins will hold the brass, MS and the tang in place. Thanks

Regards
Moin.

Bruno22 · Post by **Bruno22** » Sun May 27, 2012 7:34 am

Moin, your doing a great job. Here's something that may help you...
http://www.alvinproducts.com/products/products.asp?id=1
Will PM you the distributors email and you can take it from there.

Bruno22 · Post by **Bruno22** » Sun May 27, 2012 7:59 am

Or you can try the good old cheap n tested 'car patch' aka tinkers paste. Way stronger then any adhesives.

winnie_the_pooh · Post by **winnie_the_pooh** » Sun May 27, 2012 10:37 pm

Moin,

Have a look at this link http://www.bladeforums.com/forums/showt ... ag-Utility

winnie_the_pooh · Post by **winnie_the_pooh** » Mon May 28, 2012 10:51 am

Since you are using a grinding wheel,I would suggest you have a look at this also

http://www.grindwellnorton.co.in/grindi ... safety.pdf

Moin. · Post by **Moin.** » Mon May 28, 2012 12:28 pm

Bruno22 wrote:Moin, your doing a great job. Here's something that may help you...
http://www.alvinproducts.com/products/products.asp?id=1
Will PM you the distributors email and you can take it from there.

Thanks a ton Bruno. Looks like a very good product. Got your PM, have dropped him an email.

Thanks Again
Moin.

Moin. · Post by **Moin.** » Mon May 28, 2012 12:44 pm

winnie_the_pooh wrote:Moin,

Have a look at this link http://www.bladeforums.com/forums/showt ... ag-Utility

Thanks a lot Winnie for the both the link, the blowup of the knife is very helpful. I am a registered user at Blade Forums, do lurk around a lot but have never posted.

I do take of all safety precautions while working on any power tool. Have seen some terrible injuries while using grinders etc, so I tend to be extra careful.

Regards
Moin.

Bruno22 · Post by **Bruno22** » Mon May 28, 2012 3:58 pm

Good eye wear is a must. Also fine particulate dust from grinding can cause serious lung damage.

Moin. · Post by **Moin.** » Sat Jun 02, 2012 7:12 pm

Instead of adding just wooden slabs on the brass, thought of adding additional strenghthing on the handle as per eRajat's advise instead of Iron using brass

Chucked the idea of having brass spine, instead added jimping on the spine using a hacksaw and fine file. and Yes brought a vice as per Bruno's advise. What a dumb $%^ck me , why did'nt I think of this before, makes the job so easiermrgreen:

The pieces of brass will be glued tonight and after the epoxy sets , holes drilled and brass pins added...

Rajat · Post by **Rajat** » Sat Jun 02, 2012 7:28 pm

Wow! That's a nice vice!

Looking forward to more pictures. The rectangular style of jimping has come out very well.

Moin. · Post by **Moin.** » Sun Jun 03, 2012 11:05 pm

The brass pieces were glued with Epoxy and clamped in a vice overnight. After the epoxy had set hard, filed the desired shape. The Epoxy's set very hard, chucking the idea of having brass pins, don't think these are required.

The Leaf shape was sanded till the spine thickness was reduced by slightly more than an mm. With the heavy brass bolsters in place and tapering of the leaf shaped section, the balance of the blade has shifted from the tip towards the handle (**Exactly what I wanted). Was trying something fancy with the jimping,(stepped profile) ruined it and had to do some damage control.

Not very clear in this pic but the spine tapers down/ thickness reduces by slightly more than a mm .

Moin. · Post by **Moin.** » Sun Jun 03, 2012 11:21 pm

Rajat, Bruno- I am toying with the idea of making my own Micarta for this blade. Read some nice tutorials over the internet. Seems fairly simple. Any suggestions for a local substitute for these slow setting epoxies.

http://www.cartercrafts.com/micarta.htm

http://www.britishblades.com/forums/sho ... intensive)

http://straightrazorplace.com/workshop/ ... erial.html

Thanks
Moin.

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