The way I went about making the ones I posted pics of recently is as follows.
- Make a cardboard template of the blade, measured the thickest point of the spine with callipers and mark this on the template.
- Mill up the two pieces of timber taking in to consideration the finished thickness you are aiming for. With the small pairing and petty knives I was only aiming for 2.5mm side walls after cutting the pocket/mortice, with the big heavy western deba I went for 4-5mm. My (and most thicknessers) can only mill down to about 7mm safely so, finish with hand planes.
- Mark the inner faces with your template, leaving a little extra room around the tip area, set the trim/small router to half the depth of the spine and rough out the recess.
- Clean up with chisels and router plane
- Test fit sides firmly clamped still just right, a couple of mine ended up tighter after glue up.
- Glue up
- Mark around template leaving desired margin
- Square top edge with a plane so that you can cut the entrance end nice and clean/square on the table saw or shooting board.
- Rough out the shape on the bandsaw or with handsaws, clean up with rasp and spokeshave.
- Cut desired round over on router table
- Sand and finish (I used my own Beeswax finish).
I realise that the above lists a lot of tools that the non woodworker may not have but there are work arounds for most things in woodwork if you are keen/research enough.
Happy Making!
