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Garry Keown

Presentation box plus knife and gun

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One of the gunshops here has asked me to do 4 presentation boxes. Three will have a 1911 Colt, mag and some ammo with one of my posket ranger knives. Pistol and knife to have ebony handles with the fourth box to have a US navy engraved Beretta M9.
There will be the Spartan Molon Labe symbol etched onto brass discs to be inlaid into the knife and pistol woodwork with a larger one on the box along with my makers mark and a tag with my details plus one with the shop details engraved on it.
I have started to make the boxes from macrocarpa (Monterey cypress) and they will be lined with blue felt.
I picked up the first of the etched discs but have the tags and more discs to still be done.
The smaller discs are 18mm and the larger one is 50mm diameter.

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Sounds drool worthy, I would love to see the sets once done!

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38 minutes ago, Gerhard Gerber said:

Sounds drool worthy, I would love to see the sets once done!

I will add updates as this project progreses Gerhard.

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Picked up the rest of the discs and tags today so this will be a set for one box. 

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While I was picking up some more wood for the boxes I saw this piece of fiddleback and just had to have it for knife handles athough not for this project as they will be ebony.

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This is a very cool project. Following.

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After further discussion with Shane from Kelly country I am going to do the three knife handles and 1911 grip sets in different woods as a "this is some of what we can offer example", so after the call, I had a time of reflection on the different wood colours and it seems that they may be best shown against different coloured box linings so I have decided (I will tell Shane later :)the first set with ebony will have the box lined with the blue, the second set will be with walnut with green box lining and the third set will be the fiddle back macrocarpa shown above and that will show best against the red lined box. 

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 spent a couple of days making jigs so I can do the box inserts to hold the knife, pistol and mag and had them all just right when the nlyon collar on the dewalt rounter base let go and I ruined  one of the jigs, so am getting the engineer to make me one all in steel which will put me back a few more days on that side of things as I have asked him to make it with the collar only having a stand off of 4mm instead of the 15 that the dewalt nylon one had. This has necessitated making all new jigs which I have now got done with the primary insert cut out and will wait till I pick up the new collar on friday before I cut them for the stand off.
Needing some way to hold the 7 rounds of 45 acp I cut and drilled these ammo blocks then duncked them in the BLO tin for ten minutes. They will sit at one end of the box and should look the part when it is all together. Only had 3 rounds but enough to show the easy grab eft above the block.

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Looks good!  Too bad about the router base collar.  I hate when an otherwise decent tool is crippled by corporate greed.

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Have these four all ready for hand sanding and etching(2 random and 2 ladder pattern), and hope to pick up the router collar tomorrow and a new dovetail cutter to move forward with the boxes. Ground a pair of field scalpels and a tool I hope to use to shape the 1911 grips with so they have been hardened and in the tempering oven at the moment.

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Posted (edited)

Have my router back in working order now after picking up the new steel collar. I asked him to make it with a much smaller collar for the 6mm bit so with a 9mm hole and a 14mm outside dia, I ony have a 4mm standoff as opposed to the 15mm standoff for the nylon collar. This is as I recieved it

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and after a bit of re-modeling

 

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Edited by Garry Keown

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Posted (edited)
Made some more progress today with the jigs finallised and the first prototype sorted out. I had made a couple of boxes with mitered corners as it was quicker but will dovetail the actual boxes. I need to change the bearing from the 34 inch to 1/2 inch to suit my dovetail table. 
This is how it all needs to be done to get to the finished form.
First I needed to decide how the items would fit in the box and to make it small enough to be practical while not making it too crowded. Draw onto thin board and cut out the patterns.

 

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 From there I needed to transfer these marking to a jig board and add the stand off for the collar after checking that the cut out was still the right fit for the items. 

 

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Because there had been a few failures with the jigs I ended up making a separate jig for each item although with the first collar having the 15mm standoff the cut outs ran into each other so it was necessary 

 

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A few failures for the scrap bin

 

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And when it all came together I was abe to mock up the first box athough having to use a replica 1911 for now. I have made the cut out for the 1911 slightly oversize as it will have to accomadate most of the different makers offerings and I had to take this into account. 

 

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Edited by Garry Keown
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That's coming along nicely Garry.  Will you somehow be including a sheath for the knife as well?

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4 hours ago, Alex Middleton said:

That's coming along nicely Garry.  Will you somehow be including a sheath for the knife as well?

Yes there will be my standard (45*) cross draw sheath as an unfitted accessory Alex. This will work with most 1911 carry options.

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Blades handsanded and etched this morning

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Stunning blades, and the boxes are coming along nicely!

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Had a good day in the shed today with the boxes all assembled and in the camps for the night. Then I made a start on the 1911 grips. I cut the knife handes and the grips at the same time from the same blocks to keep them as simiar as possibe A set each of ebony, walnut and curly macrocarpa. I had stabilised a pot full of blocks last week to make sure these were all given that extra protection against warping or shrinking.

I glued the slabs together by taping each piece and putting a couple of spots of superglue between them so they are easy to take apart again. This made it easier to cut and sand them to the same profile as the sample ones I had 

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I needed a way to hold them while shaping them so made a jig that works quite well.

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From here I used a 60 grit bet to rough in the curved surface and then made a scraper from a bar of 1075 and hardened it . I use the smaller side to check the top end and the larger curve to scrape it to shape. I did the curly macrocarpa set first as they have the most difficut grain to work with and I thought if I could get them right the others would be much easier. 

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A bit more to go but pleased to get them to this stage. I have to try and source the correct counter bore bit to get the screw holes to the right diameter. 

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10 hours ago, Garry Keown said:

I glued the slabs together by taping each piece and putting a couple of spots of superglue between them so they are easy to take apart again. This made it easier to cut and sand them to the same profile as the sample ones I had 

I've been trying to figure out how to do this easily, and once I read your solution it now seems so simple!  Thanks for sharing that tip!  What kind of tape do you use?  I fear that super glue may soak through the wrong tape; or the tape would fail while working the wood.  

Also, it is unfair to present those blades for people to choose from.  I certainly couldn't pick a preferred pattern as they are all great.  I'd probably have to choose based off of what handle material was currently available and go with that.  Then the sales guy would say something like "Garry could make any combination of these".  To which my reply would be "NOT HELPING!"  

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1 hour ago, Jerrod Miller said:

I've been trying to figure out how to do this easily, and once I read your solution it now seems so simple!  Thanks for sharing that tip!  What kind of tape do you use?  I fear that super glue may soak through the wrong tape; or the tape would fail while working the wood.  

Also, it is unfair to present those blades for people to choose from.  I certainly couldn't pick a preferred pattern as they are all great.  I'd probably have to choose based off of what handle material was currently available and go with that.  Then the sales guy would say something like "Garry could make any combination of these".  To which my reply would be "NOT HELPING!"  

I used ow tack painters masking tape Jerrod. The same tape I use to wrap my blades after hand sanding and the super glue does not penetrate through that. 

We will be offering any combination of handle material that I have on hand or can get for these box sets.

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Posted (edited)
1 hour ago, Jerrod Miller said:

I've been trying to figure out how to do this easily, and once I read your solution it now seems so simple! 

I don't want to take anything away from Gary's approach as it is fine.  It reminds me of an old woodturners trick, that I thought I'd share.

You can take 3 pieces of glossy magazine page paper and sandwich it between your wood parts with old fashioned wood glue.  Once dry the stack will behave like one piece of wood.  However, a razor blade pushed into the magazine paper seam will separate the pieces with no fuss whatsoever.

I used to do this all the time back in the days when I was turning finials and trim to restore antique clocks.  You could turn two identical 1/2-finials at the same time this way :)

Edited by Brian Dougherty
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Thank you gents!  I had a grip for my fencing sword that needed to be re-made, and I did not figure this out before hand.  I just made two over-sized pieces and finished them once assembled.  This will certainly be an improved method next time!  

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Garry, the Damascus patterns are superb, high praises for sure, IMO. I also like the scraper idea and I would like to try it on some ideas I have, if you don’t mind!

Gary LT

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41 minutes ago, Gary LT said:

Garry, the Damascus patterns are superb, high praises for sure, IMO. I also like the scraper idea and I would like to try it on some ideas I have, if you don’t mind!

Gary LT

This damascus is not something I have made myself Gary. I buy it in from Creative man in Australia. https://creativeman.com.au/steel/

Making scrapers is something I have done a lot of from when I was making rifle stocks from the bank and needed different shapes for some of the inetting tasks. A good way to re-use od files.

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That's okay Garry, still beautiful in these knives. I have old files also, which can be "donated" for a "handle - Sen"

Gary LT

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This thread is full of great ideas and methods so far.

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Some progress amongst the setbacks. The box inserts I had made were going to make it difficut to do the felt linings so I had to make another set and another jig to cut the 1911 grip and mag butt end out as it needs the full depth of both the main 9mm primary insert as well as the 6mm lower insert where the balance of the 1911 and the remainder of the mag along with the knife handle only need the primary (9mm) cut out. I also made another set of boxes as the first set were a bit cramped depth wise. 

They are all sanded back to 80 grit and the edges radiused so ready for the hinges and locks now before the finish sanding. I had intended to put my 3 dot makers mark on the lid via drilled holes filled with black epoxy but decided to use the head of some siicon bronze nais after trying them on a scrap piece. 

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