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 Post subject: M390 Ultimatum WIP!
PostPosted: Sun Sep 09, 2012 8:43 pm 
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Location: CT
One of Marks customers in Canada had his Ultimatum sent to me sans handle. The plan was to use some Red Buffalo Horn, SS Spacer, Black Buffalo Horn, SS Spacer, Bog Oak, SS butt cap for the handle and do a D shaped handle, which I have never attempted before.

First up, I wanted to epoxy the SS/Horn/SS together so I could drill thru it all at once:
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Next step was to cut the Bog Oak block, and the Buffalo Horn:
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Aluminum tubing cut:
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Next I drilled a 1/2" hole thru the spacer sandwich, around 1.75" into the Bog Oak, and partway thru the Buffalo Horn and then slot the Buffalo Horn. Nothing really exciting there!

All of the pieces lined up on the aluminum tube, made sure it would fit nice on the tang. I ground a tiny bit off of the tang to slip into the tubing.
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SQUISH!! All of the parts are epoxied onto the aluminum tubing and clamped:
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While that was curing, I did a rough cut out of the Aluminum end cap. The SS would have added a pretty good bit of weight and I found some 1/8" aluminum, so I went with that. It will be drilled for a 1/4" Mosaic pin and the pin will be inserted into the end of the Bog Oak a little to strengthen the joint there.
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 Post subject: Re: M390 Ultimatum WIP!
PostPosted: Sun Sep 09, 2012 8:49 pm 
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Once the epoxy was cured on the handle, I broke out the coarse, nasty 36 grit belts to rough out the handle. With the SS spacers, they got hot quick, so you have to go light and dunk the handle it water to keep it cool. Buffalo Horn doesn't like to get hot, either. Here it is roughed out:
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Butt end and front end views. You can see that at the butt end, the D line dropped a bit to the midline instead of the upper half of the handle like the front was. I had looked at my other knives and I wanted that line a bit above the centerline all the way through.
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I went to a 60 grit and then 120 grit belt and got the center line up a bit:
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At a 320 grit finish, I got that D line up where I wanted it between the belt sanding and hand sanding:
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Another shot:
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Spacer rough cut:
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Spacer epoxying:
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Ok, now I'm all caught up! I gotta go out, and clean up the spacer and blend it to the handle and then polish it a bit. Next update should have the handle pretty much done!!


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 Post subject: Re: M390 Ultimatum WIP!
PostPosted: Sun Sep 09, 2012 9:56 pm 
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Ok, back from the shed!

Aluminum butt cap rough filed to the handle:
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And I mean rough filed!
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Aluminum is fairly soft and cleans up easily:
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All done! Polished the aluminum up a bit more, cleaned up the handle and sanded it with the Micro Mesh sandpaper to give it a nice, smooth finish:
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Aluminum Buttcap polished up:
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Light is failing, so I got these quick shots of the whole knife. I will probably epoxy the handle to the tang tomorrow:
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Handle close ups:
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Not bad for my first D handle! All in all, pretty happy with this one. The butt cap came out pretty cool! The one thing I am bummed about is that the Red Buffalo Horn turned out to be more like Brown Buffalo Horn when it was shaped and finished. Apparently, the dye barely penetrates the surface and once you sand past it, it looks like regular buffalo horn. There may be a slight reddish ting to it, but it may be because they used lighter horn to dye in the first place.

I will get some better pics tomorrow in better lighting and see if there is any red or not.


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 Post subject: Re: M390 Ultimatum WIP!
PostPosted: Mon Sep 10, 2012 1:40 am 
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Awesome dude, that's a sheek looking handle, you got some serious talent. :)



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 Post subject: Re: M390 Ultimatum WIP!
PostPosted: Mon Sep 10, 2012 1:42 am 
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Thanks! This was a fun project. I had to think a little out of the box from the normal Western handles I usually do. I picked up a Dremel Router/Shaping table to help make the slot a little straighter. Now I gotta figure out how to work it a little better, but the groove was straighter than when I did them freehand!


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 Post subject: Re: M390 Ultimatum WIP!
PostPosted: Mon Sep 10, 2012 4:25 am 

Joined: Wed Jun 06, 2012 2:06 pm
Posts: 20
i cant wait to get this knife. it looks amazing.

tim you are really passionate and it shows in your work. thanks.


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 Post subject: Re: M390 Ultimatum WIP!
PostPosted: Mon Sep 10, 2012 9:16 am 
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Location: Cape Town - South Africa
Very nice WIP write up + beautiful end result as well!

Well done!

:)



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 Post subject: Re: M390 Ultimatum WIP!
PostPosted: Mon Sep 10, 2012 1:27 pm 
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Handle shots. There is a slight browish/red ting to the ferrule in bright light, and there is some white feathering in there, too, so it looks a little different from the black buffalo horn spacer.
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Whole knife:
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 Post subject: Re: M390 Ultimatum WIP!
PostPosted: Mon Sep 10, 2012 3:16 pm 
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Joined: Thu Jun 14, 2012 3:58 am
Posts: 105
Love the WIP. The handle looks like it will feel real nice in the hand...



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 Post subject: Re: M390 Ultimatum WIP!
PostPosted: Thu Sep 13, 2012 6:54 pm 
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Joined: Tue Apr 24, 2012 7:32 pm
Posts: 101
Taz, As we say in Massachusetts, your handle looks absolutely Pissa Man!


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