I became interested in bladesmithing by watching the hit TV show Forged in Fire. A few years back, I was on vacation and saw an ad for a 2hr knife making class with a past Forged in Fire contestant. My wife encouraged me to give it a try, thinking it would allow me to scratch an itch but boy was that a mistake. After making my first railroad spike knife, I was hooked! I started out tinkering for fun and gave my first projects away as gifts. After some encouragement from friends, I began taking custom orders and selling my work. I now operate a small workshop where I produce 2-3 knives a month as a part-time bladesmith.
Every knife begins as a bar of high carbon steel; my favorite types are 1084, 80CRV2 and 15N20. I use a propane fueled forge to heat my steel to about 1500+/- degrees so that I can shape the metal on my anvil. Once my pre-form shape is done, I anneal the steel to soften it and make it easier to fine tune on the grinder.
I then refine the profile on the belt grinder and drill pin holes for the handle. I heat the steel back up and normalize it to shrink the grain structure and reduce stress. After that, I quench it in specialized oil to harden the knife. It then gets cleaned and tempered in an oven for multiple 2 hour cycles to take out the brittleness.
I then go back to the grinder for clean up and finishing the bevels. Next, I prepare the handle material by rough shaping it on the band saw and sander. The scales get epoxied on and cure overnight. Then I can contour the handle, hand sand up to 1000 grit and apply wax. I put the final edge on the blade using wet stones and a leather strop.
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