Select and label the “scales” for the handle1. The pieces for the handle are called “scales” and can be cut

from domestic or exotic hardwoods, acrylic, bone, antler or other suitable material. (They are not included with the kit.) For this kit, start with scales that are at least 3" long by 11⁄2" wide and 1/4" to 3/8" thick.

2. Identify the Left and Right Scales and determine the inside

and outside faces. Label accordingly. (As used here, “right” and “left” refer to the sides of the handle as oriented when the tool is held in the hand with the blade extended, edge down.)

Cut the scales1. Measure the distance between the shoulders of the metal

Front and Rear Bolsters on the Knife Body (1). (It should be around 23⁄8".) Cut the scales slightly long and then test fit and trim to achieve a snug fit.

2. Fit each of the scales onto the knife and use the body to trace the final outline on the scales.

3. Using a coping saw, scroll saw or band saw, cut the scales slightly oversized, at least 1/16" outside the trace line.

1

Folding Pocket Knife Hardware Kit Instructions57735

Danger indicates a hazardous situation that, if not avoided, will result in death or serious injury.

Warning indicates a hazardous situation that, if not avoided, could result in death or serious injury.

Caution indicates a hazardous situation that, if not avoided, may result in minor or moderate injuryor property damage.

Notice indicates important or helpful information and/or user tips.

> Please read these instructions completely before beginning.

> Be aware that the blade comes sharpened. For your safety, cover the edge with several layers of painter’s tape before you begin working on your custom knife kit. Remove the tape after assembly is complete; if necessary, remove any adhesive residue with hot, soapy water or acetone.

Scales for handle sold separately

PARTS LIST Quantity

1 Knife Body 1

4. Sand the scales through progressive grits, up to 600.

5. Apply the finish of your choice to the scales, keeping in mind that, as the knife is handled, the handle will come in regular contact with oils that could degrade the finish.

6. Polish as desired.

57735Rev 04/18

For additional questions contact SARGE Customer Serviceat 800.454.7448

Blade is very sharp. Cover with layers of tape while working.

2

Mount the scales1. Apply a thin coat of CA glue or epoxy to the inside face

of the Left Scale and press against the left side of the Knife Body (1). Clamp in place and allow glue to cure.

2. Apply a thin coat of CA glue or epoxy to the inside face of the Right Scale and press against the right side of the Knife Body (1). Clamp in place and allow glue to cure.

Shape, sand and finish the scales1. Cover both Front and Rear Bolsters with masking or foil tape

to avoid scratching them.

2. Begin the shaping process with the scale edges that abut the Bolsters. Using flat and round files, a power sander or handheld sandpaper, shape the thickness and profile of those edges to achieve the desired transition between the scales and the finished metal surfaces.

3. Shape outer edges of the scales flush with the Knife Body (1) and refine the thickness and profile of the handle until the desired contour is achieved.