Handle Screwed On

Hi, I appologize for the lack of piuctures since I'm transitioning to a new phone. I spent about 2 and a half hours in the shop starting at 4, drilling a fourth hole in the handle and drilling holes for rivets in the buckler's plate. I had much help and instruction from Don in all of this, especially because he knows how to use the drill in ways that I don't. Attached the handle with screws and nuts to see how it all fits, and it's looking pretty nice. I am quite sure, however, that the handle is not thick enough for a good grip. The buckler is of thin-gauge steel and therefore not really suitable for fencing in the first place, but with the thin handle it rotates in the hand too easily. I don't think I feel like forging a new handle at this late stage, but if I were to make another buckler I would choose much thicker stock to begin with and make sure the handle was thick enough to be immediately serviceable. The only question now is how to modify the current handle to fill the hand, and prevent it from twisting in the hand too easily. It's meant to replicate a fighting weapon; it has to do what I want it to do, not rattle around in my hand.

Monday, October 21, 2011: Medieval Chest Plans; Rivet Holes

I came in at 4 today and stayed until 6:30. I checked back in with Don, who's been away for a long time recovering from a heart attack. At Tom's suggestion I deepened the boss a little more and practiced fluting on some scrap metal, since I was intending to emboss eight to ten radial flutes on the buckler coming out from around the boss. Don suggested I drop that idea in the interest of time and not stressing the metal further. Instead I spent the day drilling rivet holes in the handle. Don and I talked about how we'll make our oak chest, and agreed on a design that I will perfect during Thanksgiving break. So far, so good.

November 3, 2011: Handle nears completion

Today has been very satisfying. Thinking that the handle was still too long, I decided once and for all to just make it the exact length needed to span the boss. I reforged the handle one more time, made it as straight as I could, and when i saw it was right I called it a wrap. All this re-doing of my work has made me more confident and nimble, from the way I hold the tongs to the ways that I use the anvil as a surface. All this work on the handle hasn't been a waste of time, but rather a trial-and-error session. I also finally memorized the steps for hooking and unhooking the propane to the furnace. With my new, well-forged piece, I cut off the end tabs with the bench shear and set to work at the belt sander. Glen showed me how to adjust the former, Don how to use the later. I'd seen Bea using the belt sander to get pits out of her blade, and its worked wonders for the handle. The black coating and rust on the metal is gone. I worked out various techniques for getting all the sides, trying to get as smooth and rounded a surface as possible. Gently turning the various edges along the belt many times produced very pleasing curved surfaces, and at the end of the night it shone like nothing I've seen in a long time. Now it feels, looks, and fits like its almost ready to get riveted on. After going over it with the brush one more time I should set it aside and get back to work on the buckler's disc. I started the work day at 3:43 and ended at 6:17.