IMAGE #1 The author uses two different
methods for buttcap construction: one with
screws (left), the other by welding (right).
Photo by Lori Szilaski

Q: I like hidden-tang construction on my knives. The only problem I have is when I put the buttcap on the handle. For that construction I use two flat-head screws to secure the cap. I am always very careful to countersink the holes for the screws but when I grind the screw heads flush with the cap, a hairline circle appears where the screws are. This bothers me a lot. Any suggestion or tips you could provide would be appreciated.

I use a couple of different methods. One is with screws and the other is by welding (see Image #1). 

To make the buttcap using screws, I first select material for the cap that is thick enough for this type of construction.

The reason I say thick enough is because you will need to drill and tap the buttcap plate for two screws. I cut the plate to the proper size for the buttcap, then I mark and center punch where the screw holes will need to be. Then I set my drill-press depth so that the drill bit will not penetrate further than half the thickness of the material.

Once the proper size holes have been drilled, I tap them with a bottom tap. After that, I cut the screws to the proper length, and then put a nut on each screw before I screw them into the plate. Then I hard solder the screws to the plate for extra strength.

A buttcap made in this fashion has to be pre-shaped to the handle as closely as possible. If you are going to dome the buttcap, take care not to grind off too much material or you could end up with the same problem—the screws will show.

The second method I use is similar but I weld a tab onto the center of the buttcap. I cut some grooves, what I call glue grooves, into the tab. 

I also cut glue grooves into the handle on the inside of the tang hole. For this, I use air rotary tools, but you could also use an electric rotary tool such as those by Dremel® or Fordham®. I use different-size ball bits, depending on handle size.

Combining the glue cavities cut into the handle, the grooves cut into the tab and the nuts used on the screws, you create a strong foundation to hold the epoxy and the cap in place. Over many years of using either method, I have enjoyed great results and never experienced a problem. 

I hope you give one of the methods a try. You can decide which one is easier for you or which one fits your tool setup best. The welding method is preferable if you need to use thinner material on the buttcap. There are several variations of these methods that are also used.

The author answered this question in the August issue of the 2008 BLADE.

Send your questions for Wayne Goddard or Joe Szilaski to BLADE®, POB 789, Ooltewah, TN 37363-0789 BladeEditor@fwpubs.com. Include a self-addressed, stamped envelope with your full name and address for a personal response from Wayne, or e-mail him at wgoddard44@comcast.net. If you would rather contact Joe by e-mail, his e-mail address is joe@szilaski.com. If you wish, BLADE will not print your name with your question.