How do we make our wooden handle scales?

At Valli Forge, creating wood handles that are both beautiful and durable is what we’re passionate about. Our process starts with carefully selected domestic woods and ends with perfectly stabilized handles, ready to stand the test of time. By using Cactus Juice Stabilizing Resin, we ensure each piece of wood is strengthened to resist environmental changes without losing its natural charm. Here’s an inside look at how we do it.

Handpicking the Finest Woods

We don’t just work with any wood—we specifically source premium, domestic varieties like walnut, black walnut, cherry, butternut, maple, ambrosia maple, and burl cherry. These woods are not only known for their strength, but their stunning grain patterns make every handle one of a kind. I source my materials as locally as possible. That being said - if you have any special handle material requests - reach out eric@valliforge.com

Step 1: Vacuum Infusion with Cactus Juice

The process kicks off by submerging the wood in Cactus Juice Resin. This resin is perfect for stabilizing porous materials while preserving their natural beauty. Using a vacuum at 30", we extract all the air trapped inside the wood, allowing the resin to seep into every pore. The vacuum runs until no more air bubbles appear, signaling that the wood is fully saturated.

Step 2: Pressure Pot Perfection

After the vacuum process, the resin-filled wood blocks are transferred to a pressure pot, where they’re treated at 80 PSI for six days. This step ensures the resin penetrates deeply and evenly, significantly boosting the wood’s structural integrity.

Step 3: Heat Curing for Stability

Next comes heat curing. The wood is placed in a 200°F oven for six hours, where the resin hardens completely inside the wood. This locks in the stabilization and helps protect the wood from warping, cracking, or reacting to humidity.

Step 4: Cutting, Sanding, and Polishing

Once cured, the stabilized wood blocks are cut down to the perfect size for handles. From there, we sand and polish each piece with care, using 220-grit sandpaper to create a smooth, refined finish. This step brings out the natural grain and beauty of the wood, making each piece a true work of art.

Step 5: Stored with Care

Finally, the polished wood scales are stored in a humidity-controlled environment. This ensures they remain stable and ready for use whenever they’re needed, whether by our craftsmen or by customers creating their own handles.

Why Stabilized Handles Matter

For us, it’s about more than just making strong handles—it’s about making something that lasts. With Cactus Juice Resin and our meticulous stabilization process, Valli Forge handles aren’t just tools; they’re lifelong companions. They retain the natural beauty of the wood while gaining the strength to endure years of use.

Whether you’re looking for finished handle scales or want to try your hand at making knife handles yourself, we’ve got you covered. Soon, we’ll even be offering pre-made handle scale and pin kits to help bring your knife-making projects to life.

At Valli Forge, we don’t just craft handles—we craft trust, quality, and artistry.