Make your own Micarta® style material (pic heavy)

[Adam Savage]

Here is a brief description, of how to make your own Micarta® style material, for knife scales and liners.

First off the list of things you need...

Cotton, Canvas, Hessian, Denim, or similar...this is the main ingredient. What you choose here, will determine the colour and texture of the finished product.
Epoxy resin (and a fair bit of it). I use fibreglass resin, as it is easy to get hold of, although it does have a slightly orange tint to it.
Greaseproof paper.

Tools and equipment...

Scissors (or a sharp knife and steel rule) to cut the fabric into strips or squares.
Two pieces of hard flat material, to press the fabric/epoxy mix between.
Several clamps, or clamping devices.
Something to mix the epoxy in (old takeaway boxes or butter containers work well)
Something to spread the epoxy (piece of stiff plastic or old credit card) DO NOT USE CARD or WOOD.

First step, cut the pieces of fabric to desired size, and enough to make the thickness you require...

http://i1024.photobucket.com/albums/y304/crazysaint22/projects%20and%20equipment/101020111139.jpg

http://i1024.photobucket.com/albums/y304/crazysaint22/projects%20and%20equipment/080920111019.jpg

Then prepare the lower clamping surface, by covering it with the greaseproof paper...

http://i1024.photobucket.com/albums/y304/crazysaint22/projects%20and%20equipment/101020111141.jpg

Mix your epoxy...

http://i1024.photobucket.com/albums/y304/crazysaint22/projects%20and%20equipment/101020111140.jpg

Then apply a good coating of epoxy to the greaseproof paper, lay the first layer of fabric onto it, smooth out the fabric (removing any creases or air bubbles), then coat the layer in more epoxy. Do this with every layer after, ensuring that everything stays nice and smooth.
Sorry I don't have pictures of this stage, as epoxy sets quite fast, and time is of the essence with this stuff.

Once all the layers are covered in epoxy, place another sheet of greaseproof paper to the top, before placing the upper clamping surface on the lot. Clamp the two boards (or whatever you used) starting at the middle, working your way to each end (this reduces chances of ripples, etc)....

http://i1024.photobucket.com/albums/y304/crazysaint22/projects%20and%20equipment/101020111142.jpg

Leave for a couple days (the epoxy will take a while to cure right in the middle of the fabric) and you should have something that looks like this...

http://i1024.photobucket.com/albums/y304/crazysaint22/projects%20and%20equipment/121020111155.jpg

Trim off the excess if you want, or you can just cut the shapes/scales/chunks off as you need them.

This method also works with Micarta® paper, but instead of using fabric, use coloured card. Ideal for making liners/spacers.

http://i1024.photobucket.com/albums/y304/crazysaint22/projects%20and%20equipment/041020111110.jpg

http://i1024.photobucket.com/albums/y304/crazysaint22/projects%20and%20equipment/041020111111.jpg

http://i1024.photobucket.com/albums/y304/crazysaint22/projects%20and%20equipment/041020111112.jpg

http://i1024.photobucket.com/albums/y304/crazysaint22/projects%20and%20equipment/110920111039.jpg

[JEEP]

Very interesting T^

[Adam Savage]

I ran out of epoxy for the final layer on this last one :D, that's why it doesn't go right to the edges. lol

[jbrown14]

Adam, I've wondered about making my own micarta-like material. Seeing it broken down into easy steps like this has just put another project on my large back-burner.

You should put the step-by-step together and post it on www.instructables.com.

Thanks!

Josh

[CanadianMike]

Nice work, looks easy enough!

[Adam Savage]

Thanks guys. I think there are a couple methods floating about on the net. Haven't checked instructables yet, but I would imagine someone has put it on there. I shall investigate :D

[Mountain Goat]

This will sound incredibly stupid. What's micarta?

[Adam Savage]

Not stupid at all buddy. it's a vulcanised fibre material, used by knife makers and manufacturers, for handles. Although originally it was used as an insulator in electrical units. :)

[rossbird]

Adam, your a mine of information.
Thanks

[Adam Savage]

lol, a land mine of useless **** more like haha.
Thanks RB.

[nat110732]

Thanks for taking the time to post this, very interesting and informative, ta.
do you find one particular resin works any better?

cheers nat:happy-clapping:

[jus_young]

Cheers Adam! Do you use anything to polish it up with after shaping?

[Realearner]

Can you layer different colours and when sanded would they come through?

[Realearner]

By the way, great instructional. And will have to give it ago when I get time ha ha.

[Adam Savage]

Thanks for taking the time to post this, very interesting and informative, ta.
do you find one particular resin works any better?

cheers nat:happy-clapping:

Have only used the Davids fastglas fibreglass resin, but as long as you mix the hardener right, all of the quality ones should work. I try and mix the minimum amount of hardener, just to give me a little more working time, but a word of warning...don't try and use a really tiny amount of hardener, or you will still be waiting for it to set a month from now :)


Cheers Adam! Do you use anything to polish it up with after shaping?

H haven't yet, mainly because a grippy handle is safer than a slippery smooth one, but people do polish it. Not sure what they use though.


Can you layer different colours and when sanded would they come through?

Yes, the stuff in the photo is grey and green denim (although it's hard to see). Red and black can give striking results, but even if you stick with a single colour, you can get a grain pattern appear as you sand through the layers.

http://i1024.photobucket.com/albums/y304/crazysaint22/projects%20and%20equipment/140920111056.jpg


By the way, great instructional. And will have to give it ago when I get time ha ha.

Thanks buddy. It doesn't take long to knock up, it's just the curing time lol. Make sure you have absolutely everything ready before you start though haha

[Adam Savage]

Here's a couple pics of the homemade Micarta, after trimming off the excess...

http://i1024.photobucket.com/albums/y304/crazysaint22/projects%20and%20equipment/141020111165.jpg

http://i1024.photobucket.com/albums/y304/crazysaint22/projects%20and%20equipment/141020111166.jpg

And compared next to shop bought Micarta (I made mine thinner, as it's for small neck knives, but it can be made to any thickness)...

http://i1024.photobucket.com/albums/y304/crazysaint22/projects%20and%20equipment/141020111167.jpg

http://i1024.photobucket.com/albums/y304/crazysaint22/projects%20and%20equipment/141020111168.jpg

[Mountain Goat]

Thanks

[Adam Savage]

Thanks

Your welcome MG.

Here's the homemade stuff on the knives. You can get a rough idea of the layering on the finished items...

http://i1024.photobucket.com/albums/y304/crazysaint22/projects%20and%20equipment/IMG_0010.jpg