Bowie Knife Replica Build With Stag Antler Handle

Oct 12, 2026 Last reply: 1 hour ago 3 Replies
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The detail that caught me off guard is the star emblem carved into the base of the antler handle. A rotary tool was used to carve it, and on a handle that already has a weathered look, that little touch does a lot of work. It is the kind of thing most people would skip, and it makes the whole piece feel finished.



The blade started life as a profile marked out with a ruler and marker, then cut on a band saw. A belt sander and hand files cleaned up the shape after that, and the bevels came off an angle grinder. The steel is 1095 high carbon, which for a Bowie-style blade with a wide profile seems like a solid pick in my view. Heat treating was done in a small forge heated by propane torches, followed by an oil quench and a temper in an oven. That is a proper sequence for this steel, and seeing it done with such a compact setup is encouraging for anyone working in a tight shop.



The handle side got plenty of attention too. The deer horn was filed to shape and drilled for the tang, and the blade was test-fitted to check alignment before anything was committed. The brass guard was cut, slotted, and sanded smooth, and a separate brass strip was heated and bent into a collar for the top of the handle. A pin runs through the collar and handle to secure everything to the blade. Polished brass against stag antler is a classic pairing, and the contrast in the finished piece looks strong.



One open point: the epoxy that went inside the handle was confirmed by the maker but never shown being done. I would be curious about how much was used and how it was worked in around the pin.



Project by Jumbo Radish. Watch it on their YouTube channel:

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Bending the collar from a heated brass strip rather than machining or casting it is the smartest call here. Brass moves nicely once hot, so the strip can wrap the antler contour closely. The trade-off is that a formed collar shows any unevenness more than a machined ring would, so the sanding step matters a lot. From the result described, it paid off.

How was the tang hole drilled through the antler? Deer horn has that dense outer wall and a softer, pithy core, and drilling a long hole for a tang can wander or blow out the side. Did the maker drill from both ends and meet in the middle, or ream the hole progressively wider until the blade test-fit sat square?

Since the epoxy step never got shown, a variation worth trying on a future handle is packing the epoxy in with the pin already dry-fitted, then pulling the pin, letting it cure, and drilling it out clean before final assembly. It keeps the hole from getting gummed up and guarantees the pin seats deep when it goes in for good.

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