Pockets for the knives

After completing a test piece, it was time to route out all the pockets for the knives. 19 knives in total, with the pockets to be routed in a beautiful piece of 7/8″ thick tiger maple. A little nerve wracking to say the least!

Here are some progress pictures. The Eagle head of the pocket was routed first as that was the deepest pocket.

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Next the main body of the knives were routed out.

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I then removed the 1/4 plywood template from the back of the maple. That in itself was a struggle, it’s amazing how strong double sided carpet tape is! Using a 1″ forstener bit I drilled semi circles above the template of each knife. This was to be the guide to route out a small finger pocket. I then clamped the plywood to the front of the maple and using a plunge router with a core bit and collar cut out the finger pockets.

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Here is a detail shot of one of the knife pockets.

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Finally here is a shot of the tiger maple board complete with all the knives. I was pleasantly surprised when each knife dropped neatly in it’s designated pocket 🙂

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The next step will be to make the frame of the case. I plan on using African Mahogany with half blind dovetail joints inlaid with maple.