I was recently asked by a gentleman to make a Fairbairn Sykes Agent Dagger. Being familiar with the Fairbairn Sykes Fighting Knife, I had no idea what an Agent Dagger was. As a result I had to do quite a bit of research.
Fairbairn Sykes Agent Dagger
I found the sketch of the Fighting Knife as drawn out by Rex Applegate, who worked with Fairbairn and Sykes.
Further research revealed that there were actually many variations of the Fairbairn Sykes Agent Dagger. Some we very small and fit in your lapel. Others were just scaled down versions of the Fighting Knife. I asked the gentleman which kind of knife he was looking for and he wanted a 3/4 sized version. Shortly after I went to work drawing up plans and then entering them into Google Sketchup.
I decided to use 1/4 inch thick 1075. I made the blade 5 3/4 inches long with a 9/16″ ricasso area. This basically follows the design of the Fighting Knife at 3/4 size. For a guard, I used a slotted brass guard from Jantz Supply. It has a slot 1 inch tall by 1/4 inch wide. Just in back of the blade you can see the area where the guard sits. I left a 1/16th lip of steel to prevent the guard sliding forward onto the blade. This means that my knife is 1/4 inch wider than a Fighting Knife, which had a blade height of 7/8″.
I made a 1/4″ stick tang and threaded the part farthest from the blade at 1/4 inch, 20 threads per inch. It was easy to take a piece of brass, drill a 1/4 inch hold and then put the same threads in the brass to serve as an end cap.
For a handle I chose Lignum Vitae. It is a dense, tough, oily wood that seems to work well for knife handles.
Here is a video of the entire process:
Finally, here is a photo of the finished project.