How to Make Knife Handles From Thermoset Plastic

Thermoset plastics are highly specialized synthetic materials. While most thermoplastic materials soften or melt when participating in a heat-related construction process, thermoset plastics hold their rigidity and strength with no molecular breakdown. In fact, the heating or annealing process typically increases their strength. Because of their light weight and ultra-high tensile strength rating, thermoset plastics are excellent candidates for knife handles, where repeated annealing of the blade is done. The most common designs utilize cotton fabric-reinforced thermoset plastic bar stock. Their primary usage has typically been in the handles of various tactical and diving knives.

Things You'll Need

  • Tape measure
  • T-square
  • Cardboard
  • Permanent marker
  • Straightedge
  • Craft knife
  • 1/2-inch canvas C/CE fabric-reinforced thermoset plastic bar stock
  • Power hacksaw
  • Power drill
  • Knife blade
  • 1-inch 30-degree thread-cutting steel machine screws
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Instructions

    • 1

      Draw the outline of the knife handle on white paper with a T-square and pencil. Use a favorite-fit knife as a rough model. Redraw the design until it is finalized. Redraw the final design on a piece of cardboard with a permanent marker. Cut out the cardboard handle template with a straightedge and craft or X-acto knife.

    • 2

      Trace the handle template onto a piece of thermoset bar stock. Cut out the handle blank with a power hacksaw. Hold the handle piece against the intended knife blade to verify its fit. Adjust the design if necessary and recut the piece. Repeat this process for the creation of the twin handle piece for the other side of the blade.

    • 3

      Drill four equidistant, 1/4-inch holes in the knife blade for the posts that will connect the twin handle sides to the blade. Dimensions vary but these holes should result in a five-section spacing in the handle end of the blade.

    • 4

      Use the knife blade as a template to mark the location of the holes on both handle pieces.

    • 5

      Use a power drill to drill 1/4-inch holes clear through the first handle piece at holes No. 1 and 3. Use a 1/8-inch bit to drive holes half way through that handle piece at holes No. 2 and 4. Reverse the process and drill 1/4-inch holes all the way through the other handle piece at holes No. 2 and 4, halfway through the piece at holes No. 1 and 3.

    • 6

      Mount the handles to the blade by driving 1/4-by-1-inch thread-cutting machine screws through the handle pieces, the knife blade and halfway into the other handle piece.

    • 7

      Use a power sander and metallic emery disk to sand the machine bolt heads flush with the outside surface of the handles.

    • 8

      Finish the surface of the handles, hand sanding with light and then fine emery paper