I wrote about how I make handles with hidden pins before (-click-, -click-) so I won’t repeat myself in this post too much. However, I tried that technique with something new this time – bone scales.

I am currently making two big outdoor knives with highly polished blades. Those blades alone were a lot of work so I have decided to go all the way and make the knives really posh. So I have decided to make the handles with bone scales. However, when making handle scales from bone this big, they were a bit too thin. Thus I have decided to bulk them a little bit with 2 mm micarta (dark brown for contrast). And using micarta gave me the idea to use my hidden-pin technique for bone scales too.

© Charly, all rights reserved. Click for full size.

I did not originally plan to make the pins hidden so the holes were placed just as if they were visible (I originally planned a different bolster shape too). So there are six 3 mm metal pins and 4 6 mm bamboo dowels holding the handles together now. The super big holes filled with wood were drilled so big to remove needless mass from the tang and the wooden plugs are there to increase glued surface.

© Charly, all rights reserved. Click for full size.

I drilled all the way through the micarta and about 1 mm into the bone. I would not use this technique for bone alone because it is very rigid, stiff, and brittle. But micarta is somewhat pliable, elastic, and strong both in tension and pressure so I think it is an ideal material for the transition between the metal tang and the bone scale.

© Charly, all rights reserved. Click for full size.

This gives me a nice, big surface on which to draw something pretty. I already have designs for both handles and one is half-finished.

Mechanically, I think this handle construction should withstand everything that a classic one with pins going all the way through would. As far as aging goes, the epoxy glue did not fail on any knife I have made yet, but should it fail at some point in the distant future, it should also be relatively easy to fix with new glue.