2020-03-30 (M) Electro Knife for Simulated Combat EleKSCo

Even though I started a group of black-handled knives explicitly for Grindfest, I had a clear polycarbonate handle that looked too cool to ignore. The Grindfest knives also needed the Cold Steel training knife, since that is the hardware upon which we agreed to standardize. I had a different training knife by Master Cutlery that was shorter than the standard, so I decided to combine the extra hardware into a custom weapon that I may let folks use in the exhibition matches. The blade needed reshaping for the handle, and that meant cutting it down with a hack saw, then rounding it with a hole saw and a power drill.

I drilled pilot holes in the tube, which was easy to align since the pipe was clear. The rubber blade got pilot holes next, then they were expanded to 7/32" (5.5mm). I pushed cylindrical aluminum standoffs into those holes, which was a tight fit. To get the blade inserted, I squeezed the sides of the handle with a clamp and pushed real hard.
Sized knife blade

I cut aluminum templates for this knife using the same technique I used for Velostat, but this time I bought a cutting mat. I used masking tape to hold the aluminum to the cutting mat and marked my lines before cutting them with a razor. I still cut all the curved edges with a pair of scissors. The first time, I cut two identical aluminum strips, so I had to cut a couple more for the other side, which wasn't a problem when I cut Velostat since I could glue them on either side. Now I have a pair of spares.

Once I had a complimentary pair of aluminum strips on the knife, I laid the high-voltage wires on them and covered them with a tab of tape. The last step was to glue the red switch adapter to the tube. This transparent version should make for an excellent demonstration since all the parts are visible, and it is functional.
Clear handle demonstration knife

GitHub repo for EleKSco.
The rest of the posts for this project have been arranged by date.
First time here?
Completed projects from year 1
Completed projects from year 2
Completed projects from year 3
Completed projects from year 4
Completed projects from year 5
Completed projects from year 6

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