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Merit Badge Application: Hacker

ca Offline DogNose

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Merit Badge Application: Hacker
on: September 15, 2016, 12:06:03 AM
Hi all, I'd like to apply for the Hacker badge with this thread about modifying a recent purchase - the Blackjack Knives TacOps6.

It started out with toxic green G10 handles and a first finger groove. I wanted a more versatile handle, so took some AAA curly maple and set to work.
The hope was to eliminate the finger groove with a nice old-timey tapered roachbelly style handle.
"Everybody's got a plan until they get punched in the face."
Mike Tyson


ca Offline DogNose

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Re: Merit Badge Application: Hacker
Reply #1 on: September 15, 2016, 12:08:06 AM
Got my clamp set up and lined up the dullest hacksaw blade in the house. Ground the cut smooth with a bench grinder after that.
"Everybody's got a plan until they get punched in the face."
Mike Tyson


ca Offline DogNose

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Re: Merit Badge Application: Hacker
Reply #2 on: September 15, 2016, 12:11:46 AM
Cut out a set of blocks for scales. Drilled the holes using the blade blank as a template, and sized out some mosaic pins with a brass lanyard tube.
Used 2-part epoxy and a clamp, overnight to cure.
I used the old scales as a guide to trace out and approximate the way the new handle was going to be, and used a drum sander to profile it out, a little above tang.
"Everybody's got a plan until they get punched in the face."
Mike Tyson


ca Offline DogNose

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Re: Merit Badge Application: Hacker
Reply #3 on: September 15, 2016, 12:14:36 AM
Measuring out from centre, i set up some guide lines of the deepest part of my contours, and the highest part of the palm swell... going a touch fat to give room to finalize the shape later.
I rough cut it out using a couple saws, and knocked the rough shaping out on the drum sander.
"Everybody's got a plan until they get punched in the face."
Mike Tyson


ca Offline DogNose

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Re: Merit Badge Application: Hacker
Reply #4 on: September 15, 2016, 12:19:03 AM
Hand sanded with a special block I've used in the past for just such a purpose. It's necessary to keep the pins and wood flush, and really helps with the inside curves to the finger guard, heel, etc.
I went up to 1200 grit, then put iron acetate finish on the wood. This raised the grain up, so i had to go back to 320 and work my way back up to 1500. Then I started wet sanding with tung oil. Finished with a rubbed and buffed beeswax.
« Last Edit: September 15, 2016, 12:25:25 AM by DogNose »
"Everybody's got a plan until they get punched in the face."
Mike Tyson


ca Offline DogNose

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Re: Merit Badge Application: Hacker
Reply #5 on: September 15, 2016, 12:23:10 AM
In the end, it turned out better than I'd hoped. I really like the handle now, without the finger groove. It is customized to my hand, obviously. The copper mosaic pins look really good with the iron acetate finish.
Of course, I would have done a couple things differently, and wished I hadn't rushed a few steps. Next thing to do is get a decent leather pouch sheath for it, and take it camping...
"Everybody's got a plan until they get punched in the face."
Mike Tyson


us Offline SteveC

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Re: Merit Badge Application: Hacker
Reply #6 on: September 15, 2016, 12:27:12 AM
Beautiful job   :cheers:


ca Offline DogNose

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Re: Merit Badge Application: Hacker
Reply #7 on: September 15, 2016, 12:43:02 AM
Thanks!
 :cheers:
"Everybody's got a plan until they get punched in the face."
Mike Tyson


us Offline Dean51

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Re: Merit Badge Application: Hacker
Reply #8 on: September 15, 2016, 02:19:59 AM
Good work, those handles look great.  :like:


us Offline Poncho65

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Re: Merit Badge Application: Hacker
Reply #9 on: September 15, 2016, 04:02:26 AM
It is an awesome thread and a very great walk-through of the whole process :tu: If you request the badge I am sure you will get it :whistle: Hint Hint :pok: :D

If you don't know how all you have to do is go to the top and click your name, then click awards, then click show available awards, find the merit badge you want then click request award then include the link for this thread and BAM one of us fabulous moderators will award the badge to you :D


ca Offline DogNose

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Re: Merit Badge Application: Hacker
Reply #10 on: September 15, 2016, 05:44:08 AM
Thanks Dean.

And thank you, Poncho.  :tu:
"Everybody's got a plan until they get punched in the face."
Mike Tyson


wales Offline hiraethus

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Re: Merit Badge Application: Hacker
Reply #11 on: September 15, 2016, 01:45:53 PM
Definitely counts - badge awarded.  Nice work DogNose. :tu:


us Offline Poncho65

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Re: Merit Badge Application: Hacker
Reply #12 on: September 15, 2016, 10:42:42 PM
Congrats on the badge DogNose :like:


 

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