I wanted to do something a little different than just plain Sugru though. So I attempted to embed a pattern and fill it with another color of Sugru. There was some slight distortion so the bear ended up looking a little bit like a beast from one of those highly speculative Discovery Channel specials on pre-historic animals. But overall I was happy with the result.
Step 1: Tools and Materials
- 2.5 mm allen wrench
- Utility knife
- Chisel (or other prying implement)
- Cotton swabs
- Old key card
- Something with which to make an impression
- Sugru (black and orange)
- Petroleum jelly
- Rubbing alcohol
- Wax paper
Step 2: Disassembly
WIth the knife seperated I turned to removing the Neoprene inserts. I loosened the grip inserts by cutting around the edges with a utility knife. I then attempted to prize the inserts out with a chisel. This didn't meet with success so I cut a grid into the Neoprene and popped the pieces out of the knife handle.
Step 3: Clean and Prep
With that done I then used my finger and cotton swabs to put a light coat of petroleum jelly on the knife body around the grip cavities. This was to prevent the Sugru from sticking to places where I didn't want it.
I repeated this process on the necklace I used to make my impression.
Step 4: Add Sugru
I had some Sugru left so I put it on the faces of a clamp and used the coated key card to level it out. This came in handy later.
Step 5: Add Sugru Part 2
I had a lot of extra Sugru so I used it to add a grip to my utility knife. I need to get better at estimating usage.
Step 6: Cleaning, Trimming and Assembling
Twnety-four hours later after the orange Sugru had set it was time to finish it up. I used my fingers, forceps and a probe to remove the small bits of Sugru that had adhered lightly to the knife. Most of these I was able to rub off with my finger tip as the petroleum jelly kept them from sticking tightly.
With the small bits cleared away I set about removing the excess material lumped on top to reveal the design. I clamped the knife to my bench to keep it from moving. Then I extended the blade of my utility knife as far as I could. Then I pushed the knife through the mounded Sugru sort of like a miniature planer. I repeated this until the desgin was fully revealed and the Sugru was level with the top of the grip cavity.
Once you've trimmed it reassemble the knife. One of the screws in my knife serves as the main pivot for the blade. If your knife is the same way don't overtighten this screw or you knife won't open. A little experimentation will get the knife tight, but allow it to open without resistance.