As mentioned in another thread, I'm out to build my "perfect" Juice tool. The goal is to make it KF4-sized, but trade the seldom-used saw blade (seldom used by me anyways
) for a set of scissors. I'm also wanting both knife blades to be one-hand openers. Last but not least, my perfect Juice tool needs a pocket clip.
Step 1) Obtain a reasonably priced XE6 from eBay to use as mod fodder. (none of the other standard models has all the components I need)
Step 2) Attempt to add thumb studs to the knife blades. This has proven to be extremely difficult on previous attempts. The blade steel is quite hard, and can only be drilled with solid carbide tooling.
I was able to drill and spotface a hole, but a high speed steel tap broke when I tried to add threads.
(see broken tap - gold tini coated - in the background)
Looks like the thumb studs will have to be press fitted into place.
Step 3) Disassemble the XE6. This looked much easier than it actually turned out to be.
Simply cutting off the rivet heads was only the beginning.
The purple anodized aluminum scales came off easily. But underneath, the rivets are mushroomed out into the skeletonized liners. It was a major PITA to finally get them free.
AT LAST!!
Step 4) Make new scales.
Yup, you heard me. After considering a number of other compromises, it seemed that there was no other way to properly allow room for the knife blade thumb studs, AND provide enough material thickness to drill and tap for the pocket clip. (the stock aluminum scales on Juice tools are almost paper thin, and far too weak to attach a clip to)
So, on with the new scales.
(And if new scales need to be made anyway, they may as well be made from titanium right?)
Actually these are not simply replacement scales. They are a combination scale, liner, and backspring rest. At this point they are only halfway done. When finished, they will be the same size as the original scale/liner I am pinching together in the photos.
Step 5) Modify the pocket clip.
I started off with a Knifekits.com model #23, available
HERE. Shallow counterbores were added to the face of the holes. These allow the screw heads to sit slightly more flush. They also fit very closely to the screw heads, which should minimize the tendency of the clip to wiggle.
Step 6. Finish machining the bottoms of the scales
Step 7. Install thumbstuds
Step 8. Assemble
But its late, and I'll have to do the rest next weekend.
So far so good though.
Some parting pics:
