Machining, X-files Alien Stiletto build.

I am currently building a fully functioning X-files alien stiletto. It is double action out the front, spring operated. For safety and legal reasons, I have designed two safeties into this project. The first is a weakened carbon fiber blade, that will break with enough force applied. It requires only a few pounds to do this. Secondly, I have designed a fail safe in the secondary lock, that if the blade is not defeated, it will automatically return inside the handle to prevent injury. Now that the legal stuff is out of the way...

I have about 180 hours invested in the blueprints, mock up and two prototypes. The only real reason for this, has been with the relatively small dimensions and the complexity of the mechanism. I have consulted several fellow machinists during this process and we have all agreed that with a few modifications, my initial design is sound. That being said, I have my own shop, so I can spend as much time as I want on personal projects. :cool

I was initially skeptical about showing the process and progress of my work, as I hope to sell these and I didn't want someone to copy my work... But then I realized, there is no point of me being on this forum, if I don't share my passion and my work. So if people can make this after watching me, GREAT. I will help you every step of the way. (No I won't give you the blueprints :devil.) Anything else though is fair game! I am not going to chronicle my previous versions of this, only this final, complete, working, Alien Stiletto Mk3.

To start with here are the machines I am using: a Bridgeport Mill with Acu-rite control center and a Grizzly lathe.


The materials: Starting from the left, 4 small screws that I have to turn down, 4 springs of various size, a .070" X 5" carbon fiber rod, 1" X 10" 6061 round aluminum bar, 5/8" X 8" 6061 square aluminum bar, 1 1/8" X 8 1/2" 8620 round steel bar, 7/16" X 1 1/2" 4140 round steel bar, 1/4" X 1 1/4" X 3 1/2" random plastic and a 1/2" X 1/2" X 1" 4140 flat steel bar.


Lathe tools from top left to right: Adjustable angle tool, cut-off tool, custom ground radius tool, 30 degree tool, 1/2" boring bar. Milling tools from bottom left to right: 2 flute 1/4" ball end mill, 3 flute 7/16" end mill, 2 flute 3/32" end mill and my 1 1/2" fly cutter.


Finally I have my mockup. This is obviously very rough and was only used to proof my concept, it is also much larger and without the safeties of what I will be doing. However, this is the only way to show the process from the inside. The piece on top, is actually on it's side and turned 45 degrees so you can see the channel. If you look closely you can see the spring on the backside. This piece I am calling the "Carriage". The piece laying down, with the channel facing up, I call the "Frame". At the very left of the picture you can see my carbon fiber "Blade" is set into a steel "Blade Holder", this is actually the final "Blade Holder" as the first two iterations I used brass, which galled too easily and kept getting stuck, and a 7075 aluminum "Blade Holder", also galled, thus my settling on the 4140 steel.


Finally I am not sure how the internal parts will hold up to repeated use, so I may change them after this project is complete and I do some wear testing. Why don't I just change the material now you ask? There are a few reasons. The harder a material is, the longer it takes to machine to the final dimensions, it also wears on tool bits more, weighs more and finally costs more.

I'm not sure if anyone would like to see videos of the machining process. If enough people would like to see some video, I will try my hand at video editing and speed up the process like 4x or maybe more. If anyone has questions, by all means ask away. If there is anything I missed or something you want to see, let me know and I will try my best to make it happen.

looking good!!!

That Is going to be awesome! still fall short of understanding how a real stiletto works. it's the spring. closed It has tension to open. open It has tension to close.

seems like free energy to me....

sean said:

That Is going to be awesome! still fall short of understanding how a real stiletto works. it's the spring. closed It has tension to open. open It has tension to close.

seems like free energy to me....

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The spring isn't under tension until you move the switch. Then a moment is created, wherein the spring is pulling against the blade and once the internal lock is defeated, it pops forward, or backward, depending on which way you are pushing the switch. Thanks Stieller and Sean.

Ok, so good news, bad news. I spent all day working on my spring mechanism and the aluminum "feet" failed. Due to the parts being so small, the threads basically disintegrated. That's the bad news. The good news is, I will be using 4140 steel instead and I shouldn't have to worry about them failing anytime this century. I should have the feet done tomorrow morning and pics will be posted then.

As a long time Piranha and Microtech OTF knife owner, I am following this closely. If for no other reason than to have the damn things explained! Like Sean, I never understood how the retracting spring could overcome the out-thrusting spring if it was just overcome, itself, in allowing the blade out! This looks like beautiful work and makes me want to hunt down the X Files episode to learn more about this prop!

Well with the new understanding that there is no tension on the spring until the switch is moved. this would be my stab In the dark. on the back of the spike part should be a locking notch for lack of a better term. and inside the body at both front and back there should be two locking lever's. when closed you move the switch forward to put tension on the spring and at the same time the back locking lever Is being raised out of the notch on the spike. when released the spring tension throw's the spike foreword to engage into the front locking notch and releasing spring tension. and moving the switch backward achieves the same in revers...

Let me know If I came anywhere close to getting that right...LOL

sean said:

Well with the new understanding that there is no tension on the spring until the switch is moved. this would be my stab In the dark. on the back of the spike part should be a locking notch for lack of a better term. and inside the body at both front and back there should be two locking lever's. when closed you move the switch forward to put tension on the spring and at the same time the back locking lever Is being raised out of the notch on the spike. when released the spring tension throw's the spike foreword to engage into the front locking notch and releasing spring tension. and moving the switch backward achieves the same in revers...

Let me know If I came anywhere close to getting that right...LOL

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Nailed it! I have had to make an internal frame, since I don't have the room inside that a regular otf knife would have. I also have placed the blade in between frame and carriage. You will see all of this as I go along, then at the end I will do a video showing the functioning without the outside tube and then fully assembled.

I'll be watching this one with excitement. Hopefully you'll get it down pat and can start selling these beauties.

That a #30 spindle on your BP?

Thanks Robl, I'm looking forward to selling haha. My last prototype worked, it was just ugly as all get out, as I had to mill slots down the tube to check the function. Switching to steel internals is a better idea anyways, just didn't want to have the weight disadvantage of it, but hey that's how it goes.

Node Nine it's a kwik switch II.

ahoudini said:

As a long time Piranha and Microtech OTF knife owner, I am following this closely. If for no other reason than to have the damn things explained! Like Sean, I never understood how the retracting spring could overcome the out-thrusting spring if it was just overcome, itself, in allowing the blade out! This looks like beautiful work and makes me want to hunt down the X Files episode to learn more about this prop!

Click to expand...

Uhm, in case u missed it, I posted a thread about this many weeks ago. A fully functional version already exists, but it costs ca. 2000 dollars.



Link: http://www.therpf.com/f9/perfect-x-files-stiletto-replica-need-your-help-please-211306/

Wreckhur said:

For safety and legal reasons, I have designed two safeties into this project. The first is a weakened carbon fiber blade, that will break with enough force applied. It requires only a few pounds to do this. Secondly, I have designed a fail safe in the secondary lock, that if the blade is not defeated, it will automatically return inside the handle to prevent injury. Now that the legal stuff is out of the way...

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Unfortunately I dont think the legal stuff is out the way at all. U can still poke someone's eye out with it. Technically it is still a OTF blade. Try convincing a police officer that it isnt, or try getting it thru customs if selling it internationally. :rolleyes

There are many states where OTF possession is illegal, meaning u dont have to carry the thing with u in order to be breaking the law.

Im also curious, where did u get the dimensions from? Are they screen accurate?

Notice in the pictures on this site that the tube is not straight, but thicker in the center: http://sites.google.com/site/aliengimlet/

Unless there is an impossibly complicated mechanism inside, or something proprietary, it can always be shipped in pieces...

RobI said:

Unless there is an impossibly complicated mechanism inside, or something proprietary, it can always be shipped in pieces...

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Yeah... which doesnt make it any less illegal.

BTW, a great video on how a double action OTF works: https://www.youtube.com/watch?v=8DThyzNTcM4

Jacobson said:

Yeah... which doesnt make it any less illegal.

BTW, a great video on how a double action OTF works: https://www.youtube.com/watch?v=8DThyzNTcM4

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I don't see how it is illegal to ship a pointy stick in a box. I also don't see how it is illegal to ship a metal tube in a box, springs or not. Separately they are nothing; they are not weapons. If you like, have them shipped a week apart so the two boxes don't travel together. Get where I'm going with this?

Possession of the stiletto is another matter, but who cares. It's going to be sitting on a shelf in my house. I'm not going to be walking around with it in my pocket killing aliens, unless you are.

I have already talked with my lawyer about this. There is nothing illegal about selling a toy here in the U.S. It's not a double action OTF as there is no knife blade in it.

And reality prevails. Thank you for verifying. International law may be different, but that is not your job to research it, only verify what is told to you is true...

Wreckhur said:

It's not a double action OTF as there is no knife blade in it.

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The guardfather spike doesnt have a knife blade in it either, but its still illegal almost anywhere.

So, I had a few commissions last week that I had to knock out before I got back to this. I've had a few setbacks. I am switching to more 4140 steel for the internal parts as the aluminum wears too fast. I also made the I.D. of the handle larger, I went from .4219 to .4531. I know a little over .030 doesn't seem like a lot, but in this build it is. I am reworking a few issues after a small disaster with the frame and carriage: