You can buy knife kits online that contain just the full-tang blade and pins.
Make sure that the tape completely covers the blade. This will reduce the chances of the knife cutting you, or of epoxy getting on the blade. The tape will not only keep you from getting cut while you work, but also protect the blade from getting chipped or scratched. If you can still feel the blade through the tape, simply wrap more tape around the blade.
A knife handle is composed of 2 halves, which are also known as “scales. " The tang is sandwiched between the scales. Great types of wood to work with include: apple, ash, bois d’arc, hickory, peach, pear, and pecan. [4] X Research source Hardwoods come from deciduous trees and are typically more durable than softwoods, which come from coniferous trees. [5] X Research source
How many rods you cut depends on how many holes are in the tang. Some knives have 2 holes while others have 4. The metal rod needs to be thin enough to fit through the holes in the tang. The thickness of the rod varies from knife to knife.
Don’t worry if the ends of the pins are not perfectly flat. You will be filing them down later so that they are flush with the scales.
Use a heavy-duty table-mounted vise, if possible. If you don’t have that, use 2 to 3 smaller vises instead. The plywood will protect the wooden scales from getting dented by the vises. The plastic wrap will keep the epoxy glue from getting everywhere. If you don’t have that, you can try wax paper instead.
Be careful not to cover the holes in the tang. If the scales and tang wobble, wrap a second piece of tape around the end of the tang and scales. Masking tape will work the best here because it has a strong hold but leaves little residue.
You may find this easiest to do with a drill press, but a handheld drill may do the job.
Drilling the holes and inserting the pins 1 at a time will further reduce the chances of the tang and scale from shifting. Use a hammer to tap the pins in.
It does not matter if you use a washable or permanent marker. You will eventually sand this off.
You are cutting through both scales at the same time. The pins will hold the scales together.
Use a belt sander to shape the edge. Sand the edge down with 220- and 400-grit sandpaper. Finish off with a buffer. It would be an even better idea to insert the pins into the scales. This will ensure that the scales are aligned and symmetrical.
Rubbing alcohol will work the best, but you can use window cleaner too. You don’t have to clean the wood scales. The wood is porous and textured, so it will take the epoxy readily.
If the scales are smooth on the marked sides, it would be a good idea to scuff them as well. You can also roughly sand the scales with 120-grit sandpaper. Make sure that you are only sanding the sides that will be touching the tang. [15] X Research source
Make sure that you are using epoxy glue, and not epoxy resin or coating. Mix the epoxy using a disposable tool, as it will ruin whatever you use to stir it. It would be a good idea to wear some plastic of vinyl gloves too. You can buy epoxy glue in hardware stores. Some craft stores may also sell epoxy glue.
You may have to hammer the second scale into place to ensure a tight fit. If you want to, you can coat the pins with epoxy too. This will make the bond even stronger. [19] X Research source
