Cutting Bo-Hi or Fuller in swords knives

[bubba-san]

For a long time I did them with milling machine (borrowed) . I came across this tool from a japanese fellow from Great Britton . It will accept 1/4 cutter and also 1/8" cutters . It has set screw that holds the high speed cutters in place . There is small 90 Degree rod than keeps your lines straight. Always use a good cutting oil . For a sword It takes about 2 days to cut and polish both grooves , less for smaller blades
The piece of steel I am cutting is Aldos 1075 . You can also buy blank cutters and make your own .
I use high speed M-2 steel , its to your advantage to use the best steel for cutters that you can get .
This is about 45 minutes of work . toolcuts on the pull and smooths on the push . The rest is self explanetary. www.Micromark.com carries the cutters and the blank cutters . * tools cost about 35.00- 40.00
for 8 cutters . Its a lot cheaper than a mill and requires little or no maintenanace , except changing blades once in a while . The tool can be made easily by yourself or, can be made by machine shop for about 115.00 $
Does a nice neat job but, requires some elbow grease . Heck if my old self can do it I know some of you younger guys should have no problems...... Bubba

 

[BossDog]

Exactly what was thinking about lately..
I have a need for just this kind of tool and application making a large combat type knife..

 

[kevin - the professor]

Hey, Bubba - does this thing cut better with a smaller, rounded cutter? It looks like that big, flat cutter you used for this blade would be a ton of work. I like the idea, especially since there is a traditional pattern of fullering on Chinese blades with one or two deep fullers, and one additional fuller that is just a narrow scratch.

kc

 

[kevin - the professor]

I think Bo Finnigan has offered to make and sell those. I can check who it was if anyone want to buy one. It is one of the people on a forum that I am on.
kc

 

[BossDog]

I want one..let me know how much tho..

 

[bubba-san]

Some fullers are flat , some are round .the smaller rounded ones ie; 1/8" cut pretty fast . I bought some blank cutters and made one for 1/8" 3/16" and 1/4" round cutters . I like a flat one with a small round one beneath it . There are many styles . The one in picture is 1/4" flat . Its really not hard even for old fart like me . I am surprised how well it works and keeps a straight line , that's nearly polished . The cutters are M-2 so they are tough. For the money it cant be beat. I clamp a small piece of wood to blade to use as stop ...... Bubba

PS I can check with the man who made mine for a price .

 

[Dan Pierson]

I may be interested too. Don't really *need* it now but there are blades I'd like to make down the line...

 

[bubba-san]

I will try and get in touch with man who sold it to me . Will post it as soon as I can contact him . He lives in England . I paid 115$ for it with 1 cutter 1/4'' . Bubba

 

[Josh Dabney]

Bubba,

Out of curiosity, if you had a mill in house would you still use this type tool to cut the Bo-Hi or even just as as a finishing tool to clean up the milling ?

Probably wont be fullering anytime soon mainly just curious how you'ld go about it with access to both this tool and a milling machine.

As always... Thanks for sharing !

-Josh

 

[bubba-san]

I dont really have a milling machine however, I do have a heavy duty drill press that can do light mill work . I think it would work fine as a clean up tool for millwork . Of course you have make sure both are cutting the same size and type of groove . This tool does a darn good job .
As I mentioned previously, I purchased some blank cutters so, I can make or have made some different types of cutters for fullers.
I was totally surprised on how well the simple tool really works . I left and Email for the gentleman from England who originally made it .
If for some reason I cannot get in contact with him , I would be more than happy to loan this tool for someone to copy it . I am sure tracy knows someone who can do that . Might be a good tool to market ??? Bubba

 

[BossDog]

That is a tool design that is almostnexactly ehat I was discussing a few weeks ago with my crack machinist Travis. That is why your post caught my eye. We tabled it for the moment but I will need to see about revisiting it again.

 

[bubba-san]

Tracy, If you want to borrow it to make a copy , just let me know and I will send it to you .... Bubba

 

[BossDog]

Tracy, If you want to borrow it to make a copy , just let me know and I will send it to you .... Bubba

Thanks.
I think I can get what we need from the pictures. It's fairly simple.

 

[Fred Rowe]

Thanks for sharing the information, Bubba. I have wondered for years how this was accomplished in the past.

Fred

 

[bubba-san]

No problem , if you should run into a glitch, you are welcome to borrow it..

Bubba