Since I recently finished a dagger with a fluted handle, I thought that some might be interested in how I do it. Admittedly, I am self taught in this and my technique may differ from what others use but here's a sample of how I go about it.

This first photo is the knife before fluting the blackwood handle:

My first step in fluting a handle is to cut slots in each end of the handle (the number matching the number of flutes desired). These should be only as deep as the diameter of the twisted wire to be inlayed. These slots are so that when inlaying the wire each end of it can be wrapped around the end of the handle and into the tang slot of the handle.

Once done, draw lines in pencil end-to-end on the handle connecting the corresponding slots. Then draw perpendicular lines equally spaced around the handle. The number of these will determine the amount of twist in each flute.

Once you have the grid drawn out, cut kerfs on the diagonal lines with a hack saw blade making sure that you connect with the slots on each end of the handle. These kerfs can be cleaned up with a checkering or riffling file.

Once you have the inlay kerfs cut, cut (or file) hollows between each kerf with a rattail file until you get a uniform edge next to each inlay kerf. Note: Since most handles aren't cylindrical but irregular, the hollows will be of varying widths so a tapered rattail file is needed.

You are now ready to inlay the twisted wire. For mine I used two strands of 28 gauge silver wire twisted tightly. This can easily be done with any hand held drill and a vice. Once twisted, cut sections of wire to fit the handle allowing extra so you can wrap each end around the ends of the handle. Fit into the tang slot and super glue in place.

Here's what my finished handle looks like:

I hope this little WIP makes sense and helps a little. As I said earlier, this is my own method and may vary some from others but I hope that it helps.

Gary