39 - Modular Wall Storage , страница 15
is the layout lines extend 3/i6n past the cutting edge of the blade. This provides a small relief area inside the cap so it will lit down tight against the handle.
Another thing you'll notice is the blade is wider at the end that's opposite the cutting edge. In use, this wide end is "jammed" into the recess which keeps the blade from falling out.
To rout the recess, I used a hand-held router and a simple jig, see page 30. Then I cleaned up the edges with a chisel, see Fig. 2a.
magnet. After getting the blade to fit snug in the recess, I added a small magnet to keep the cap from slipping off the knife. The magnet is epoxied in a hole drilled in the bottom of the recess, see Fig. 3. Note: I used a "rare earth" magnet because it's extremely strong. (See page 31 for sources.)
cap & handle. With the magnet in place, the next step is to separate the cap (A) and the handle (B). Since the pieces are fairly small, I temporarily carpet-taped them together and used a fine-toothed handsaw to cut them apart, see Fig. 4.
glue-up Now it's just a matter of setting the blade in the recess and gluing up the knife, see Fig. 5. Just make sure to check that the ends and edges of the pieces align. Then slip the cap off the blade to avoid accidentally gluing it to the handle, see Fig. 5a..
final shaping. At this point, you could use the knife just as it is. But the sharp edges and square corners would dig into your hand. So you'll want to shape the knife to provide a more comfortable grip.
I started by sanding a gentle curve at each end, see Fig. 6a. Then I sanded the edges to create a slight oval shape that fits my hand like a glove, see Figs. 6 and 6b.
sand bevel. Finally, to make it easy to orient the cap when slipping it onto the blade, I sanded the comer so it matches the direction of the bevel on the blade, lk