Almost every knife making video out there will go into better detail but I wanted to share my first handle replacement project.
The knife was a very old Chicago Cutlery fillet knife(current retail value ~$15) but it had sentimental value to the owner. The handle was 1/2 broken off and really chewed up and worn out.
I used a fine toothed hobby hack saw to cut the pins and remove the old scales…kinda like looking under the kitchen stove. haha
Reprofiled and cleaned up the blade with a 1×30 belt sander.
Cut and glued, pinned and clamped new handle material on. Used 2 Ton epoxy and handle wood is curly koa.
Used new dremmel to rough shape the edges and contours. Check out the snaggly old handle!
Used slack belts on sander and after much hand sanding its starting to look like a knife again…
Applied 3-5 coats of boiled linseed oil and rubbed in until there were no more dry spots.
Finished project returned to the customer last night.

Although I didnt “forge” the blade, the resurfacing and reprofiling along with the handle building qualify this(in my mind) as knife #2 that Ive made. I knew it was completed when I started to feel a bit nostalgic about it leaving…such is the way.
6 users thanked author for this post.