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 Wooden Knuckle Dusters Video
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.)
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.
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.
Glue Up The Work Piece.
Glue ups are boring. This one was pretty straight forward.
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.
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.
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.
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.
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.
Then I sanded with these sanding wheels. I got all the inside rounds with them.
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.
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.
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.
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Thanks for watching,