Inletting shield

[Paladin 51]

Here is my process for inletting a shield. Bear in mind only my second one and first of this design. I had this Cam TL29 I had made new liners and bolsters for about 6 years ago. In shaping the handles got frustrated and it has sat till about 2 months ago when I tried to finish it. Was not happy with the maple scales so decided to redo it and took some pics. Any comments welcome and I am a big boy.

Here is the donor knife.

[Paladin 51]

Removed old scales and put some African Blackwood on. Has been superglued to hold it on and holes drilled.

[Paladin 51]

Here is steel block I am using for my anvil. It came off an air press thing. Have found it usefull.

[Paladin 51]

Side view

[Paladin 51]

Here is how I have is set up. Seems to hold it pretty well but like I said only second shield I installed.

[Paladin 51]

I then drill a series of shallow holes trying to only go the depth I need. I try to drill out as much as I can.

[Paladin 51]

After drilling out as much as I can without touching template

[Paladin 51]

I then switch to a diamond burr for a dremel. Shown with 3/32 n/s pin material. I also have a smaller one but had problem with pics but looks just like this but maybe 1/16 inch

[Paladin 51]

I then put the bit all the way up in the chuck on drill press. I move my steel block under it and lower the bit. I try to find one of the deepest holes that was drilled. You can only remove very small amounts of wood with this bit so I set it to barely remove any wood. I turn on drill press and move block around very slowly and let bit cut wood. I try to get as close to template as I can but with this big of bit it won't fit precisely in all the corners. When that level is done I go back to that deep hole and lower it again. Keep repeating till you get it the depth you want. I then switch to the smaller bit that removes wood even slower the the bigger one. This time I get right up next to the template as well as the whole "floor". It does take some time and I even move bit back up in chuck so I can remove block and take under better light to check progress.

[Paladin 51]

I check it numerous times to make sure I am as close to template as I can be. Then when I think I am done I take it all apart.

[Paladin 51]

I then put some superglue gel in hole and with a few love taps with ball peen. Shabam I did lightly sand away some of the glue so you could see better.

[Paladin 51]

Knife put together and rough shaping with files.

[Paladin 51]

After a little bit of hand sanding. Is coming out pretty nice. I like it lots better than the maple. Overall I would guess I got about 3 to 4 hours in this but I did have to cut the scales out of 1.5 inch square by 4 inch long piece of wood. I do go slow as those diamond burrs don't cut to fast and they do break if you try to push the small one to fast. I just like to tinker and not to concerned about doing it in a timely manner.

Hope you liked the pics.

[jerryd6818]

Good job Ken. Looks like it was done by a true custom knife-maker.

[just bob]

That is just great and you have a lot of patience. Thank you for posting that, The small hobby type Dremel drill press would work well for that. You get set your depth and move the material underneath it.

[glennbad]

That's really cool. Did you already have the shield pattern or did you make one?

[Paladin 51]

The shield and template were bought from USA knifemaker. A little over $21 for template and like $1.06 per shield. The templates don't appear to be hardened and they have a right and wrong side. As they are cut by waterjet there is a very slight angle to the sides so in a sense one side is a little bigger than the other. I still need to work on alignment as the top is ever so slight off from being center.

[glennbad]

cool, thanks.

[johnnierotten]

That's my favorite,Ken.

[DRS]

Awesome job looks good.
Donald

[reddirtknives]

It came out Sweet... I think 3-4 hours is quite fast considering the hand work ... And I find perfectionism admirable when it comes to this Craft... Very nice So you started out (6 years ago) with just a blade and a spring? You have lots of skills going on... OH, and the shield template???? Where? who? what? punched that thing out??? Thick stock and perfect ... very cool... How many different shield templates do you have??? Mad skills... Thanks for posting your process..........

[TripleF]

That's beautiful.....and great pics with description!!!

[Paladin 51]

I did that first conversion that long ago and was not happy with how the scales turned out so I switched them. Those shields I got from USA Knifemaker. I only have 2 different templates with an acorn on the way. The time also includes tearing apart. Now I will hand sand final to final shape. I still need to learn what to do to put on a finish over the wood.

[reddirtknives]

Sorry all...It seems I missed a page ... I hate it when I'm the redundant one

[RandyFew]

What a great job! It looks like your methods were spot on.