All About Pocket Knives

I just received a piece of deer horn about 6 inches long and about 1 inch in diameter. What is the best way to cut it for new scales without wasting alot of it? ftd

You could put it in a vise between two blocks of wood and cut in half (lengthwise) with a hack saw, a table saw or a miter saw would work also but you would lose a bit more material as those blades produce more waste in a cut.

If you have to ask, the best way probably involves figuring out exactly which parts you want for handles and the sizes you need to get out of it. Everything else is scrap for now. Cover it with masking tape and sketch the outlines of what you need. Then find a bandsaw operator who can cut those lines. (Unfortunately, this isn't something I can explain how to do. A good operator can sculpt with a bandsaw, but doing so is outside every safety rule in the book.) If that isn't an option, go with Snorkel's suggestion of padding a vise and using a hacksaw.

Thin the slabs down, flatten/straighten, and flatten again. Getting the curve out is the big problem, but it can be done.

Then the easy part is over and you have to make the knife!

Jim

PS--if you are in the US, I can send you some chunks to practice on before you cut up the good one you have now. Drop me a PM and I'll get them out the door.

for cutting curved shapes in knife scales, a standard coping saw from the hardware store works great and you can cut the curved side of the scales in just a couple of minutes.

How 'bout a scroll saw. Rip it in two, shape it, whatever.