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i'm kyle i'm josh and that's mom and dad we are the royer family welcome back to the knife studio in this brand new series we're gonna make a frame handle for this massive massive double edge buoy knife it's gonna have mother of pearl inserts on the sides and it's going to be really complicated and it's going to put me to the ultimate test to be able to make it through this build the first thing we need to do with our prepared blade is work on the guard with most of my knives i like to start on the guard when it comes to the handle and then work my way back for the guard we're going to use some 1018 mild steel that's 5 8 of an inch thick went ahead and traced over my guard real roughly and cut out a piece of paper and marked it out on my anvil with sharpie that way as i'm forging this i can hold it over the mark on my anvil and kind of rough it in and get it close to what this paper template is [Music] to start off with kyle's going to heat up his garden the forge normally he would use the torch but dad already had forge hot from making damascus [Music] [Music] okay [Applause] [Music] i'm done forging the guard to shake shape i'm done forging the garden shape if it's still this the proper shape after dropping got it heated up we're going to just let it cool down kind of slowly in the electric kiln over here i don't have the kiln on or anything i just want to let it cool down a little bit slower than it would out in the open air now that the guard has cooled down we can go ahead and start shaping it there's a lot of extra material here the stock i started with was super thick our template fits nicely within the bounds of the piece so i think we're good to go i'm going to take it over the surface grinder and start grinding away this main flat area here and get it down to the right thickness right now it's a little over a half inch thick still and we need to grind it down to like 300 000 or so [Music] once kyle is done grinding the scales he takes it to the mill to get that much desired flat surface [Music] for now we want to start working on the quillians these big lugs on the ends we need to grind those down quite a bit so i have a rough layout put on here and i've also got my jerry rigged hillbilly horizontal grinder set up over here it's not really horizontal but at least i have a rest to put it against since the the sides of this are nice and square i can hold it squarely against this rest and be able to come in here with the round wheel and clean up the undersides of the guard [Music] cal takes the guard back to the sketch fine-tuning the profile [Music] i've got the inside curves of the guard shaped now we can get rid of my hillbilly horizontal jig and use the regular flat platen to grind around the outside profile of the guard [Music] and kyle needs to grind a lot of material and fast he uses the handle of a wrench to give it more leverage [Music] i'm done profiling the guard the main thing that i like to get profiled before i do the guard fitting is get the actual shape looking at the guard this way get all that stuff shaped next thing we need to do is get a nice tight perfect fit with the guard right up against the ricasso [Music] [Music] once the bulk of the material is milled away how we use files to fine-tune the [Music] guard so that was my first cycle of hammering the guard on and i can already tell there's a problem here i was a little worried the quarter inch mill bit was gonna be a little too large because the tang was only a couple of a thousandths over one quarter of an inch and sometimes those those mill bits can wobble a little bit especially in my grizzly mill because of that i have a little bit of a gap on the sides of the guard fit-up area so we're gonna have to do some special stuff that i i don't like doing in order to fix that if you hammer on the side of your guard it will fit tighter on the tang of your knife [Music] that's looking much better i think i still have a little bit of a problem spot so i'll have to smash down on a little bit more [Music] you can see where the grinder is hitting right here the the metal that kind of got mushroomed out right along the edges i'm just going to try to lightly flatten this back out before we hammer it back on the [Music] blade [Music] and now for a word from our sponsor us over the years i've gotten many requests from people asking how to begin making knives and what to do once they've made their first or second one so my family and i have put together this course for people who want to begin making knives or for someone who's already dabbled around with it and done a couple but they want to advance their skills so much of what i've learned over the past 16 years has been poured into this course to help the beginner bladesmith get into knives and enjoy it you can make a beautiful clean elegant knife with very simple tools like a dremel tool files a vise a small forge be it propane or we'll also make a homemade charcoal forge i'm going to take you through the entire process of making a hand-forged clean and elegant everyday carry knife not only will this course help you out as a beginner but it'll also lay the foundation for the rest of your knife making journey the things i do and teach and the knowledge i share in this course will apply to any project you do in the future no matter where your knife making journey takes you having a good foundation to build a clean elegant and simple knife will benefit you through the rest of your journey use coupon code youtube for 20 off link in the description i was able to get rid of that gap on the sides of the guard where it fits up against the ricasso now that i've gotten rid of that mistake from using too large of an end mill bit we can finally move on to the rest of my guard fitting as per normal every one out of four knives i make normally ends up having some kind of little mistake where i have to bash on the guard like that so i wanted to show it to you guys in case you end up having a problem with your guard fit can really help you out you don't have to necessarily scrap your guard and start over you can get a couple of second chances at it sometimes if you can smash the sides of the metal in so we've already started to leave a little bit of a mark from the ricasso kind of goes right across there and there's another one on the bottom side so now that we have those marks i can do a little bit of filing right here because it's a little too tight now after hammering on it i didn't mention it earlier but i like to mill some of that out first because it gets rid of the bulk of the material and then we can come into the corners and fine-tune it with the high-speed dental burr and the microscope i used a really tiny end mill bit to cut a little bit of a relief and hog out the bulk of that material that way there'll be less to do with the high speed dental burr now i'm just going to cover everything with sharpie we're going to smash it on the knife again and it should leave a little bit of an outline where we can see what we need to remove so we can keep getting that fit over the ricasso a little bit further more and more each time [Music] rotating at about 320 000 rpm kyle will remove the perfect amount of material with his grs setup [Music] [Music] so i'm very happy with the guard fit it's super tight there's no gaps anywhere it's about as good as i could ask for sometimes these guard fits can have a tendency of being angled a little bit like this and we really don't want that because if you start doing that as we build the rest of the handle off of the guard it can kind of make the rest your handle sometimes be angled a little bit too so i was able to take this small square and just hold it on the spine of the blade bring it down to the guard and get it there nice and square the guard fits on pretty tight you got to use a hammer to get it off and you have to clamp the blade in the vise and use that special tool to hammer the guard on but here's how you take it off guard comes off of there and it comes off the guard comes off the guard is removable i used the high speed dental bur to remove the material around the border and then i kept hammering it on to leave a new fresh mark and then i'd go back to the dental burn keep doing that process over and over again once the ricosta started hitting these flat areas then i knew we were pretty much there and we had about 10 thousandths of an inch where the guard fit over the ricasso the next piece to work on is the front spacer this knife is going to have a combination of blued fittings with gold inlay and damascus fittings so the guard is going to be blue and then we'll have a damascus front spacer the frame will be damascus except for the outside part of the frame handle that'll be blued and then the pommel will be damascus and the pommel nut will be blued all the pieces have been normalized so they're ready to go for shaping and stuff like that and they're pretty soft right now so i'm going to start grinding on this piece get it flattened up get it cleaned up get all this forged scale off of here and then we'll start milling out the slot the same as we did on the guard [Music] make it flat is something kyle always says that's certainly true when it comes to making the beginnings of a spacer [Music] [Applause] [Music] once again i made a little bit of a mistake here with the front spacer i should have put my guard on and then drawn a line behind where my guard stops and instead of doing that i just kind of estimated that my front spacer would go up to this first little ledge here but i was completely off and the front spacer actually stopped before that ledge so once again i made the uh the fit a little loose on the front spacer so what i'm gonna do is just lightly smash on the sides ever so slightly it'll get it fitting nice and tight against the sides and then to fix the length of the groove i think i'm just gonna go in with the uh tig welder and put a little tiny bit of weld on the inside [Music] i think that's going to work out really well i lightly hit on the sides of the front spacer a little bit because i just needed to close that up ever so [Music] slightly [Music] we can't hammer this on yet because we need to cut some off of the bottom part of it because right now it's going to hit on this radius of the guard and it's not going to go all the way to where it needs to [Music] she i went ahead and shaped the front spacer or rather i profiled the top and bottom of it i normally like to do that before i move on to working with the tang and everything that way i know where to get all this frame and handle lined up properly with the blade that's ready to go we've got a nice tight fit i can't even pull it off by hand you got to tap on the tang a little bit to get it off which is exactly the way i wanted it in the next video we're going to move on from the front spacer and start working on the rest of the handle components like the frame and pommel and the sides of the frame and handle scales and all that fun stuff i will see you in the next video may the forge be with you bye-bye