I started off with stainless steel feeler gauge in .016, .019, .026, .030. I cut them into 6" strips.
This go around i did mostly freehand. I used a straight edge to make my lines and a sharpie. I used a carbide tip to etch the gauges before i started the grinding. I definitely recommend that step. I went with sharpie only at first and its quickly gone. Huge pain.
I used a basic bench grinder, a dremel, and sand paper(220, 400, 800,1000, 1500) for the most part. I kept a cup of water close and dipped very often to help cool the metal.
The writing on the handle area just helped keep track of thickness. This is also my "fancy" design. I made some with just unmodified handles, and didnt get the before pic. You will see at end.
I used 220 sandpaper to get the final shape. Then i went through to 1500 grit to shine up and smooth. I just threw the sandpaper in a book (i jabbed my finger several times doing without). Wrap sandpaper around sharpie to hit those rounded nooks.
This next part you may wanna skip unless you really feel you reached that elite level sanding. I believe the best book to sand is Twilight: New Moon. The tricky part(at your own risk), is doing this while reading Twilight: Eclipse...
Dont hate.
HANDLES:
For the handles i went a different route then with the basic shrink tube i previously used. I got stabilized wood, and broke it down to strips. I went for minimum 1/2" width to fit my gauge, 1/16" thick, and i went for 4" minimum length. Thickness feels perfect for me when its all said and done.
To secure the handle this go around i used JB Weld 5min set time. I roughed up the feeler gauge handle area and the wood to help it stick. I just used the basic clamps in picture from home depot for a dollar each. They have perfect pressure. Takes very thin amount of material to stick, wipe of excess. Sets very fast. I let cure overnight.
After that i just shaped to desired look. You will see 2 styles i tried. Version 2 was the basic round, 3 was the "fancy". Mind you i have zero artistic ability. DO NOT use grinder to shape. You will blow your handles all to crap. Best results were just hand sanding 220grit.
Once i got shape i was after, i sanded just like picks. Got through at least 800grit. Then i polished with Hut ultra plastic polish. These next couple show what i got at finish.
I have bad lighting but you can see pretty well. The stabilized wood gives a really nice shine. If you take the sanding really high with micro mesh, and use good wood , you can get an amazing look. Its really not hard and gives you an alternative to shrink tube.
This is my first step by step on my process, so if i left something off just ask. If you have ideas to better it, feel free to share. Im really happy with the outcome.
Thanks
Mean Gene
