Wooden Knuckle Dusters

By December 8, 2015Builds, Projects
The finished brass knuckles.

In this article and video, I’m going to show you how to make wooden knuckle dusters, also known as wooden brass knuckles. Here are the knuckles, finished. Take a look, and let me know what you think in the video comments.

The finished wooden knuckle dusters, or wooden brass knuckles. This is how you make wooden brass knuckles.

This is what the finished wooden brass knuckles looked like.

The Wooden Knuckle Dusters Video

I also made a video tutorial and posted it to my YouTube Channel, or the video itself can be found here “How to make wooden brass knuckles“, or watched below right here on my website:

Along with the video, here’s a tutorial showing you how I made them.

I Re-Sawed The Black Walnut.

When you’re making wood brass knuckles, you need to start out with the right material. I only needed a couple feet of black walnut, so I picked it up at the Home Depot. I re-sawed it down to 1/4″ thick, so I got two pieces out of the one 4/4 board. (Material like this from the Home Depot isn’t real 4/4 material because it’s S4S, but let’s save the lumber-nerd stuff for later.)

I re-sawed the black walnut and maple on the table saw.

I re-sawed the black walnut and maple on the table saw.

And Re-Sawed The Curly Maple.

I re-sawed the maple as well, but if you notice I have the maple’s grain running oposite the grain of the black walnut. When I glue them both up this will add strength to the brass knuckles, wooden knuckles, whatever. You know what I mean.

I re-sawed the maple on the table saw.

I re-sawed the maple on the table saw.

Cut Everything Down To Size.

Next, I cut everything down to a manageable size. This is pretty self explanitory. But, as I was doing this, I wasn’t paying attention and experienced some serious table saw kick back. Check out the video, stay safe in the shop and keep making saw dust.

I cut all of the pieces to length and width.

I cut all of the pieces to length and width.

Glue Up The Work Piece.

Glue ups are boring. This one was pretty straight forward.

I glued up the black walnut and curly maple pieces.

I glued up the black walnut and curly maple pieces.

Clamp It, And Let It Dry Over Night.

Clamp ups are even more boring, but I need to show all the steps. I absolutely love these harbor freight clamps.

After I glued the pieces up, I clamped them and let them sit over night.

After I glued the pieces up, I clamped them and let them sit over night.

 Glue The Template To The Work Piece.

This is my brass knuckle, or wooden knuckle template. I haven’t decided yet if I’m going to give this out. It is a simple drawing, I looked online and took what I liked, and got rid of what I didn’t like. And this is what I came up with.

I printed the template, glued it to the work piece with some spray adhesive, and then punched the center of the holes with an awl.

I printed the template, glued it to the work piece with some spray adhesive, and then punched the center of the holes with an awl.

Drill Out The Holes On The Template.

I drilled out the holes. I came in from the top, just deep enough for the tip to break through the bottom but not go all the way through and chip it out. Typical strategy, I know. Then I flipped it over and finished the holes out from the bottom.

I drilled out the different sized holes on the drill press, with forstner bits.

I drilled out the different sized holes on the drill press, with forstner bits.

Cut The Template Out On The Band Saw.

I then cut out the rest of the template on the band saw. You could do this with a jig saw or a hand saw. You don’t need a band saw to make wooden knuckle dusters.

I then cut out the rest of the template on the band saw.

I then cut out the rest of the template on the band saw.

Round Over The Edges.

I only rounded over the edges that would be in contact with your fingers and palm. I thought it looked cool to have square edges everywhere else.

I rounded over all the edges that would be in contact with your palm and fingers.

I rounded over all the edges that would be in contact with your palm and fingers.

Sand Everything.

Then I sanded with these sanding wheels. I got all the inside rounds with them.

I sanded, and sanded, and sanded.

I sanded, and sanded, and sanded.

Keep Sanding.

Then I sanded by hand, from 150 all the way down to 220. It took forever because there are so many curves, dips and doodles on these little things. But eventually, I was very happy with how smooth I got them.

I sanded some more. And I kept sanding.

I sanded some more. And I kept sanding.

Applied Some Tung Oil.

I applied some Tung oil, because I like how it makes the black walnut look and feel. And then 3 or 4 coats of clear satin poly to protect the wooden brass knuckles.

Then I put a coat of tung oil on them, because I like what it does to the black walnut.

Then I put a coat of tung oil on them, because I like what it does to the black walnut.

And This Is What They Look Like.

They came out really nice I think. I like the balance between violence and beauty. And they’re going to make some great “man gifts” this Christmas.

This is what they look like before the clear coat.

This is what they look like before the clear coat.

If you liked this and would like to see more, subscribe here below and on YouTube @ https://www.youtube.com/user/adamgabbert.

Thanks for watching,
Adam