The Best Way to Cut Hidden Tang Handle Slots?

I've found a new (to me) way of easily cutting slots in hidden tang handle material. This has shaved hours off my handle prep. I hope it helps
Links to video specific items:
Wen brand Momentary Power Foot Switch
amzn.to/3uYFxBA
Freud 3/32" Router Bit:
amzn.to/3kSfGJg
Freud ⅛" Router bit
amzn.to/3YrGLR5
Makita Router
amzn.to/3SXDJmK
Makitia Plunge Attachment
amzn.to/41R7glP
Makita Plunge Router Kit
amzn.to/3yAnJhb
Links to equipment I commonly use in the shop:
Heavy Duty Momentary Power Foot Switch
amzn.to/3rChd66
Wen brand Momentary Power Foot Switch
amzn.to/3uYFxBA
Harbor Freight Maintained Power Foot Switch
www.harborfrei...
Harbor Freight Momentary Power Foot Switch
www.harborfrei...
EVISWIY 30 Bulb/6 Watt with Diffuser (My Choice)
amzn.to/3jDOnOp
Harmiey 36 Bulb/8 Watt
amzn.to/3jUy5Bb
Jen-Ken Vertical Airbath 21:
knifekilns.com...
This is an independent review-these were not gifted or sponsored. The links above contains an affiliate link of some items I use-if you click it and make a purchase, I’ll receive a small commission, at no extra cost to you, which helps me continue to churn out helpful (I hope!) content.*
Questions? I am ready to help-comment below and I'll respond as soon as I can. While I have you here, please like and subscribe!
Follow me on Instagram! www.instagram....
Like me on Facebook! www.facebook.c...
Stabilized (by me) wood blocks on Etsy: www.etsy.com/s...
Website: Coming soon!

[@jeffgray5295]

Great idea! Thanks for sharing. I love your casual, but informative format. Feels like I’m hanging out in a friend’s shop picking up tips.

[@Hathenbrucksteelworks]

I truly appreciate the kind words. Thank you!

[@adelacour]

That was really enlightening, it has given me a an alternative to struggling with drills and files. Thanks for sharing.
Andy UK

[@Hathenbrucksteelworks]

Always glad to help. Thank you!

[@jeffreycarter1223]

Absolutely genius, use what you have to the fullest. It’s not about the tools you need it’s about knowing how to use what you have.

[@Hathenbrucksteelworks]

Thanks a ton for that. I totally agree. I think most of us have tools that we don’t use to their fullest potential.

[@jeffreycarter1223]

The dark side of the shop is my favorite part. Makes my crappy shop seem lest crappy knowing everyone else has ghetto homemade areas

[@Hathenbrucksteelworks]

Hahahaha. I like to believe that most of us have ghetto shops.

[@andrewneilson227]

This is genius. I’ll try this for sure. I want yo do hidden tang knives but I always botch the slot

[@Hathenbrucksteelworks]

Thank you! I like doing hidden tangs much more this way.

[@brysonalden5414]

Nice work-around! I suspect you still want a mill as much as I do, but this is a good way around that expense.

[@Hathenbrucksteelworks]

Thank you! I do want a mill at some point, but I need more space and more justification to buy one. Hahaha. Metal bolsters won’t work too well with this technique, so there’s one good reason for the mill.

[@lescargo1159]

Well that's pretty interesting, im just not cozy with the fact you need a router, make a jig, setup everything.. but probably the fastest way to make it when you have a bunch to do.
I rarely do hidden tangs stuff, and i always struggle when it comes to that part. Using files to make the adjustement but it's never perfect.
If i have to do it again i would make a thiner wood guard, maybe 8 mm thick. marking the slot with razor blade, drill 2 holes in it and then use a mini wood chisel to cut a perfect fitting.
Doing it same way you do inlaying. + using hand tools like wood chisel is super fun. But definitly not the fastest way :D

[@Hathenbrucksteelworks]

If you already have the router, it’s much easier to get into. I never get the results I’m after when I drill and file. This has been the best technique for getting a nice tight fit, without using a mill.

[@Hathenbrucksteelworks]

That way seems like it’d work really well.

[@stevesyncox9893]

Cool idea. Thanks

[@Hathenbrucksteelworks]

Thank you 😁

[@andyc750]

great job on that one, a couple of useful tips there as well as usual, do like the use what you have way of doing things, very different to my hidden tang handles, but then I use wind dropped wood from the huge amount of local trees in keeping with keeping things traditional style, can't wait to see the finished knife, going to look awesome as usual I suspect

[@Hathenbrucksteelworks]

You’re always too kind, Andy. Other than making a better, adjustable jig, I really like this technique.

[@timhorton555]

I'm sorry. I got a cross slide vice and an end mill bit for the drill press. As long as the rpms are high and you don't push in too far and proceed gently, it won't bother the drill. Or get a cheap drill press for the job.

[@Hathenbrucksteelworks]

There are definitely many ways to do it. I think what it boils down to is which tools you have and which tools you want to purchase. I recently purchased a mini mill, so this technique will probably be retired soon.

[@HobHob-vu4un]

Very cool I am also a beginner blacksmith and love the copper Damascus edc knives

[@Hathenbrucksteelworks]

I appreciate the comment. Yeah, I love copper. If you ever have any questions, don’t hesitate to ask.

[@HobHob-vu4un]

Could you make gold Damascus or brass Damascus I think it would look really cool

[@Hathenbrucksteelworks]

I know I can put layers of brass in with steel Damascus, which is something I’m going to do pretty soon. I’m not rich enough to mess with the gold though 😂

[@valiantforge]

Great idea! Definitely a cheaper router to go

[@Hathenbrucksteelworks]

Thank you! It’s been working really well for me.

[@ClenioBuilder]

👏👏👏👏👏🤜🤛

[@Down_Time_Productions]

That is most certainly NOT "the best way"

[@Hathenbrucksteelworks]

Apparently it isn’t the best way for you, but thanks for the comment.