box for the explorer

The explorer comes in a custom,handmade black paper box.

test prototype explorer

The explorer prototype has gone through various important tests in order to check stability and grip during hard use, sharpness and lockup of the linerlock.Once used as a survival tool ,this knife will experience lot’s of abuse, pressure and forces.Already the very first explorer is designed and built in answer to those needs.

Cutting into very dry wood is one test to get an idea about sharpness and stability.The lock could resist the forces from stabbing and chopping.The handle felt comfortable in any grip , several positions are possible .The knife really feels good.

Next knife will be a framelock explorer made from 10 parts.The minimum in materials but with maximum safety,comfort and reliability.

to be continued…

customizing pivots

The pivot assembly of a folding knife really needs extra attention.The right size of washers,exact pivot hole and most of all something to avoid the rotation of the pivot screw.I have been using several ideas like a press fit or modified pivot head close to another knifepart.Some knifemakers uses a tiny screw in the pivot heads area to keep it fixed.Now I am trying to use D pivots to avoid the loosening of screw.First I grind the shaft of the pivot into a D-shape , it’s done with a fine sanding belts and simple jigg.The jigg is guided  by a steel bar and a few clamps to optain a perdendicular grind.The washer prevents the belt of damaging the inside pivots head.On the left you can see a small screw which enables a tight fit of the pivot against the jigg.The pivot has a clockwise thread so I set up the pivot on the right .Otherwise the downwards pulling belt should loosen the pivot easily.

The grind only takes two seconds.There is no need to grind the full shaft of the pivot because I also use G10 as parts of the knifehandle.Most important is the straight and stable set up to avoid damaging the pivot.

5 minutes works and several pivot are done.Now its time to deform the titanium pivot hole into a D shape.

explorer prototype

A new folding knife is born ! This knife ,the explorer is my first collaboration with another knifemaker Antoine Van Loocke and comes in a limited production run.I am working on a extra page to explain the origin, purpose and proces of this tactical folding knife.

alternative drill work

For many knives I have been using commercial available pivot screws.There good for most of the folding knives and it’s easy to find the matching step drill bits . Now I am making 2 prototype folders for a design contest and I decided to use custom pivot screw parts.A special knife needs some extra attention so I ordered large 1/2″ head  pivots . A big difference to the common 5/16″ head of the smaller pivots.These custom made pivots still have the same shaft dia 7/32″ but to drill the 1/2″ recesses into the G10 I need a uncommon step drill.Custom step drills are expensive and hard to find so I tried some alternative way to counterbore the material.Below a picture to compare the sizes.

Instead of using a common step drill I start with a wood drill bit of the size 1/2″.The sharp point enables boring at the exact location in the G10 and makes the right form to bore the center with a steel drill bit.The recess is not flat but the outer diameter is the exact size and thats most important .

Now I bore the center with a smaller drill bit .Here you can drill the right size to allow the pivot’s shaft but I used the matching size of another step drill.With a smaller step drill I flatten the bottom of the bored recess.Finally a larger drill bit is used to allow the pivot shaft.

Now I flatten the inside of the recess with a special file .Once clear the pivot head fits.Shortening the shaft or head of the pivot is done later when assembling the knife.

That’s it , with a few drill bits the job is done.Of course it only works in G10 , micarta , carbon fiber or wood .