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B. Norris

Rus Sax with Bear Theme WIP - warning picture intensive

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Finally some progress with this project. Feels good to be getting somewhere with this.

 

First off, the pommel. I ended up using punches, etc., to stamp the pattern in because, the transfer of toner to the brass, using an iron, did not work. Not enough heat, I think, and with all the pressure and moving the iron around - the design smeared. I think the technique would work well with thinner brass or if I used a different heat source but, no time to experiment right now! Yes, Jol, it would have looked better if I had cut out around the bears head's with a jewelers saw or chiseled some of the brass away to create more definition but, that will have to be saved for the next one.

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An overview of all the parts, at least, that are done. Still have a few to go.

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Closeups of different parts of the sheath. Just like the originals, the design is different from side to side.

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Here is the backside of the pommel plate, showing how I used a dremel to remove some material from the backside to aid in fit up (lots easier to only remove material at the edges, to flatten.) As a bonus, it gives more room for the epoxy and provides a stronger joint.

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Same thing with the wood on the handle but, a little out of focus, sorry.

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Next up, putting it all together!

 

~Bruce~

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Pictures of the stamps, punches, and chisels, used. Mostly stuff I made, quite a few re-purposed concrete nails there! I wanted to make a better ring dot stamp (using the stamp here) but, the steel of the stamp was quite a different beast than thin, non-ferrous, sheet!

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Test pieces. The triangle punch, with 3 dots inside, worked well on the thin, soft, copper and even the thicker copper but, not nearly so well on the brass I bought for the sheath. I annealed after stamping and before flattening but, in the future, I think I will anneal before stamping also.

Rus_Sax_small_image_027.jpg

 

~Bruce~

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That pommel cap looks great,Bruce! As does the sheath...

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Almost done! Too much snow on the ground to photograph in the good light outdoors so you will have to put up with lighting from a window.

 

Here is the pommel of the knife, in the sheath.

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One side of the sheath.

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The other side.

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Here is a picture showing the welt of the sheath. I tried something that I saw on an artifact and added brass sheet into the welt. I assume this was done originally to help stiffen things up and to keep the rivets from crumpling into the leather instead of forming a head when you try to rivet them into place. I did not have a piece of brass long enough to do it in one piece and therefore used three. The welt has bumps where I overlapped the plates (not the brightest idea in hindsight.) I still had difficulties with the rivets crumpling but, using thicker sheet would probably solve the problem. I was using 1/16" brass rod for rivets and going to a larger diameter might also solve some problems.

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The dye for the belt loops is drying and then I can put them on, do a final pouting of the sheath to the knife, dress the edges, seal the leather, sharpen the knife, and it will be done!

 

~Bruce~

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Good job on the sheath, this type is trickier than it looks... I love the punched design. Yes, 1/16" rivets gave me hell on my first few of this type, switched to 3/32" rivets and it was so much easier, in fact I've never had another rivet problem once I switched.

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Do you preform one side of the rivet before attaching it to the sheath?

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George,

I will be switching to 3/32" for the rivets on the next one! Thank you for that, by the way.

 

 

Miles,

I use a little jig I made from two pieces of angle iron. Just some short sections, clamped together, with a shim between them, then drilled out to the size of the wire/rod. The shim is necessary so that the two pieces will clamp and hold the wire/rod when placed into a vise and tightened down. Then I can form the head on one side ahead of time. I could snap some pictures if you want, it is dirt simple. I was excited about this sheath because, it was ordered in brass, and my local Ace Hardware carries brass tacks, so I thought that I would not have to make all the rivets myself. When I went to buy them, they had discontinued them and no longer had any in stock. I could get them through the mail but, did not have time and it was too much of a hassle at that point.

 

~Bruce~

Edited by B. Norris

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Finished!!!

 

Well, other than the lack of my makers mark due to the etching machine not working after the last knife. Grrrr. Thinking about moving to a stamp, the etched mark has been a bit of a hassle and looks out of place on the historically inspired pieces. Anyway, here are pictures.

 

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~Bruce~

Edited by B. Norris

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That really looks great Bruce, love the pommel cap! (I use the same angle iron jig for rivets, and use a hollowed post locked in a vise for doing the other side) thanks for the offer though, and the entertaining post, magnificent work!

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