Knifemaking: on the people we hold dear, and the Bob

“I want to go back in time, because I’m a celebration in the making.”
― Francis Dunnery, “Autumn the Rainman

About eight years ago I really needed a job. I had been fired from my previous job and had been piecing everything together for about 6 months. It was not going great. I was barely getting rent and health insurance paid and my girlfriend was getting ready to leave me. A friend of mine told me to give this small company a call- they were always busy and always needed good help.

I called and spoke to the operations manager. I told the ops guy I was looking for a part time job- I had a small custom knife shop and I played music and I needed to have time to do these things. I think he probably thought I was a crazy person. He told me they didn’t do part time work but said I could send my resume and come in for an interview. Options were pretty limited at that point so that’s what I did.

I went in and did an interview. He told me this was a good place to work- the place did well. The gig looked insane. There was a warehouse slam full of skids of gear to be sold, and stuff everywhere. They looked super backed up. I don’t know if my resume was that impressive or I made an exceptional first impression or they just badly needed help, but I told him I could give him 3 days a week and he said OK.

So that’s what I did. I had two shop days a week and went in three days a week. I would build my schedule around getting into my shop, or doing crazy contractor gigs, or whatever I had to do to try and fill out my bank account. For the first two years I was afraid they were going to fire me but nobody ever gave me a hard time about it.

Within two months a being there they sent me to Atlanta to get some equipment for resale from a major client and make sure it all got loaded to get back to our warehouse. I hung out with a high level corporate engineer all day and we talked about knives and municipal engineering of their major corporate campus. Gear got back to our shop, and everyone was happy.

I did the part time thing for five years. Sometime during the pandemic everything started getting really expensive. My rent was going up about 30%, groceries were getting ridiculous, and I was seriously wondering how I was going to make ends meet. I was doing a lot of really interesting work but none of it was paying quite enough. 

About this time the ops guy asked to speak with me. The company was doing well, but a lot was in short supply, including finding help. He asked me what it would take to get me there more. No pressure he said, but take a few days and look at my numbers and let him know what my time would be worth to be there more.

There were some good paying gig that I really enjoyed doing that were sort of dried up from the pandemic. There were other things I had been doing for over a decade that I was just kind of tired of. Honestly I had been trying to figure out a way to get out of some of the things I had been doing. I was doing really good work in the shop and playing a lot of really good gigs on the weekend. It felt OK to let those other things go.

So I gave the ops guys a number. Nothing crazy but a number that would buy me out of most of the stupid shit I was doing to make ends meet. He said not a problem. I asked him if I needed to write up a CV of the stuff I had been doing around there. He said no need, it was already handled. And that was that. I told him I kind of suck at company culture, and I’m kind of a combative employee but this place had been a good place to work and always kept me safe. They did things for me that they didn’t have to do, especially during the pandemic, and when all my other stupid jobs told me tough shit, figure it out.

Within about 4 months of getting a raise my credit score went up 300 points. I didn’t have to do stupid contractor work, I could focus on doing good work on knives, and I could play killer gigs all over the mid-Atlantic coast. Looking back I wished I had figured all of this out a decade earlier, but these are the paths that make us who we are.

…..

Sometime in September of this year the ops guys asked me if I could do a kitchen knife for his wife. It would be a tribute to her father. The way he spoke of his father-in-law I thought he was still alive. It wasn’t until about 15 or 20 minutes into the conversation that I found out he had passed twenty years earlier. I thought that was really special the way he spoke of the man and the affection that was there.

‘We just talk about him all the time,’ said the ops guy.

The ops guy had said his father-in-law was the sort of guy who could do anything and was curious about everything. He told me all these stories about the man, who was a representation of a generation passed. In his later life he lived in a trailer in the woods with half a million dollars worth of tools, automatic weapons, electronics, and gadgets.

We were talking about what to call this knife. He had bought an old machine shop sometime in the 80’s, and there were all these old work uniforms left in there, which he started wearing. They had nametags stitched on the shirts, all of which said ‘Bob’. So even though his name was actually Roger, everyone called him Bob. I told the ops guy we absolutely have to call this knife ‘The Bob’. These are the sort of special builds that makes this craft worth doing.

They still had Bob’s work clothes, and allowed me to make them into a handle material. Turning this man’s possessions into handmade kitchen tool to be used everyday seemed the best way to celebrate this man that everyone held dear. I started with a 8′ chef knife design:

Template is made

Drilling the rivet holes. I like to put a countersink in about a third of the way through the thickness of the steel on either side. This will allow for a bit of play during fit-up and ultimately makes for a tighter fitting handle.

Blade profile is cut and smooth.

Centerline is scribed. The cutting edge is intentionally left thick and will be ground thin after heat treat.

A bit hard to see but I have put a radius on the spine. This will make for a more comfortable pinch grip. If you are a chef swinging one of these for 8 to 10 hours a day, a square edge can lead to bruising on the index finger.

Ready for the forge. I’ve removed a bit of material while the steel is soft to establish the bevel. It will make it easier to get an even grind once the steel is hard.

I harden the blade before it is fully ground because long and thin blades like to warp and crack when heated.

Quenched. She is nice and straight with no cracks.

Full flat grind. This is off the grinder at 220 grit.

Hand sanding to remove the machine marks. Windex helps the sandpaper cut better.

Satin at 400 grit. Ultimately this finish took about two hours per side.

Handle time. Bob’s work clothes. Mostly polyester, which will give a more defined ‘grain’ on the final product.

Getting everything cut up into uniform pieces. It’s impossible to find good help these days.

Mise en place

As each piece gets stacked, fiberglass resin gets spread. This will turn about 16 pieces of Bob’s pants into one solid slab that can be worked and polished.

This gets clamped up. We want to smash everything as evenly together as possible. As the resin cures through the porous material everything will bond together.

I always mix a little extra. Fiberglass resin is an exothermic polymer and will naturally heat up as everything starts to catalyse. The melted cup tells me the mixture is curing properly and I mixed everything correctly.

Turned out nicely with a tight grain.

We follow the same process for Bob’s work shirt.

This material is a little thinner, so we try to do more layers.

Everything did what it was supposed to.

This also turned out nicely.

A leaf from a dining room table. It was pulled out of a lawyers house during an estate sale. I believe it is walnut or cherry.

The pants will make the bolster part of the handle.

The lawyer’s table will be the butt of the handle. We want the grain to be parallel with the length of the knife.

Everything will fit better if the rivet holes are drilled before it is cut in half. Because of the way this is made, the wood will be bookmatched.

PCB board blank. These were scrapped at work a few years ago. It actually has two sheets of copper just underneath each side. I’m not sure if they were supposed to let me take them but nobody has missed them.

That little flash of copper will be a subtle pop.

Countersinking the rivet holes will give a little play when fitting the handle. There are no precision tools in the shop and this will help negate any incongruencies I may make when trying to get this all together.

We need to polish this before fit up since we won’t be able to get at it once everything is fit up. 120 grit.

2000 grit.

All the pieces parts.

All glued and clamped.

Time to take away the parts that can’t be held

Profiled.

Flushed up.

Contoured.

He’d have been fired long ago if he weren’t so cute.

This is what it looks like at 220vgrit. We will take it up to 2000 and then buff.

All said and done we will probably do five coats of this stuff

Adding our mark.

The alligator clips are attached to a 6V battery. The nail polish acts as a resistor and current is only run to the area I marked. Connecting the circuit with the positive end through our conductor (salted vinegar) will burn our mark onto the steel. You have to use iodized salt- that delicious pink Himalayan sea salt won’t work.

The namesake of the knife gets etched onto the other side.

The Bob.

Knifemaking: courage in being gentle, and the Tennessee Gentlemen

Play that restless melody for me again
The one I’ve been so afraid of,
My sweet friend.
Maybe the little refrain will whisper inside the rain again
Play the one with all the changes
.”

Al Jarreau- “Something That You Said

Sometime in the beginning of the pandemic I started talking like Hulk Hogan. Just before everything got shut down I had been making combat daggers for spec ops guys. They had gotten in touch with me asking for “something that you can ram through somebody’s skull.” They all had a particular way of talking to me. The first time I talked to any of them they always addressed me as ‘sir’, and every interaction thereafter was ‘brother’. I really dug that. Even though they were paying me for a service, it made me feel like we were all on the same team and working together.

‘I APPRECIATE YOU, BROTHER!!!’

I found that to be immensely encouraging as I noticed it slipping into my vernacular. The irony of all this happening while I was building them tools of combat to rain down pain is not lost on me.

As Covid started shutting everything down and civil unrest led to riots, I found most of my means of livelihood shut down. Everything was a mess and I was broke trying to pay medical bills. The State Unemployment system was, and is still, a joke. With the murder of George Floyd, and everyone already agitated from lockdown, there was lots aggression and anger. Some of that aggression and anger manifested as marches through the streets, and some escalated to shopping centers being burned down. States of emergency were declared, riot police were dispatched, curfews were instilled, teargas was launched. Most all of this was happening less than a block from where I live, and occasionally it crossed over to the front yard of my building. There were nights where I was afraid someone was going to set my car on fire, which was how close this all was. My Buddhist vegetarian yoga teacher (who didn’t eat meat because it was unkind to animals) told me she was thinking about getting a gun and this did not seem unreasonable to me.

Everyone has the potential to fall prey to their baser of inclinations and move through life as a wrecking ball, especially when a private ambulance company is overdrawing your bank account because your livelihood is shut down like a high school keg party. It was my goal to not do that. During quiet moments at that time, I would check in with myself just to see what was hanging around. I found myself to be full primal rage, an ocean of grief, a profound sense of loss, and a hair-trigger response to any perceived threat. At such a reactive time as it was not too long ago, I found that it took a tremendous amount of courage to be kind and gentle.

During one such quiet moment I asked myself if we could break every interaction down to the very simplest parts of humanity and connection, and just not worry too much about the rest. Maybe we could find a way to let go of the weight of fear and uncertainty, and surrender to the simple joy of quietly going about one’s day. As a result of stripping everything down to the simplest parts of connection during a time of extreme duress, I found myself thinking of the Spec Ops guys for whom I was making daggers. I thought particularly of how in the course of our business I always felt seen and heard, and that my time and talents were respected and honored.

The crux of the Hulk Hogan technique is that it allows the people you interact with to also feel seen and heard. For me it was something that replaced a feeling of despair and hopelessness with a sense of community and belonging. It kept me safe and connected and prevented me from being a wrecking ball, which was what I felt like most of the time. In practice it started every morning with the gentleman selling me my coffee at the market down the street.

“IT’S GOOD TO SEE YOU, BROTHER!”

He got some encouragement and I got some coffee. Everybody feels better and has a bit more confidence for their day in a world that is on fire.

As I prepared for my days of shit work to keep myself from being sued by private medical companies, I did my best create disarming moments, as much for myself as the people I interacted with every day, starting with a cup of coffee. There is great power in gentleness, and after all the anger and violence I had experienced, I wanted to see what that practice looked like. Turns out it’s a bit like starting a chainsaw- a gentle but purposeful tug on the pulley cable gives you enough power to take a tree down. Pull too hard and you break the thing.

Ladies I talked to were always “Ma’am”, and anyone I believe to be identifying beyond the binary was always “Cousin”.

In focusing on my interactions with others, I found my crankiness and shit attitudes were curbed. They didn’t go away and I still found myself frustrated at the world, but those moments were much smaller and less consuming. It was much more than an affectation- I had absolutely fuck all going on and this was where I could direct my focus. After such a traumatizing time, this was a way that I could come back to myself and remember who I am and what I do.

Any sort of practice, when diligently observed and worked on, operates on a continuum. It meets you were you are and expands into everything. I was having a drink on my girlfriend’s porch one night when my girlfriend pointed out her neighbor struggling to get a washing machine off his pickup truck. Without thinking I got up and went over.

“BROTHER DO YOU NEED A HAND?!?”

…….

This two knife set was build for a good friend of mine in Tennessee. He got in touch needing something better for his kitchen. During hunting season he and his wife process a lot of deer. After field dressing, a good set of kitchen knives are good second-line tools.

When we spoke over the phone, he had said that while he had needed a set of knives, he had also wanted to throw me some business and help me to practice my craft. As a craftsman himself, he understood. He did to me what I had been doing to everybody else for the past two years, and this build was a lovely experience and testament to the courage of being gentle. I’ve detailed that experience below.

A critical mistake was made here. Rivet holes should always be drilled after the slot is cut and fitted. Lesson learned.
Fitted
Hardening the Chef.
Rough grinding.
Rough grinding on the Boning knife after hardening.
A nice radius put on the spine.
Laying down a hand rubbed satin finish.
600 grit.
Getting ready for fit up.
Sanding the Chef.
Satin.
Making sure everything lines up.
….and everything did not line up. I broke two drill bits trying to get everything lined up before epoxy cured. Epoxy cured and I have to rip everything apart and figure out what everything wasn’t lined up. This was the third attempt and everything finally went together.
Hnadled up with Ebony.
Shaped.
For the Chef we have reclaimed Cherry, recovered from an old mantlepiece.
Preparing the brass bolster.
Peened and fitted.

Knifemaking: an unexpected party, and the Cowpoke

“There is nothing like looking, if you want to find something. You certainly usually find something, if you look, but it is not always quite the something you were after.”
― J.R.R. Tolkien, “The Hobbit, or There and Back Again

My Dearest Young Friend,

I was told you have made it eleven times around the sun this year. Eleven! In celebration of this, your dad commissioned me to make you a special knife, which was convenient because I prefer to make knives that are special regardless! I like to make them out of things I find- in fact, the knife I made you was made out of materials that I found in the garbage. The blade is made out of an old bedframe that I can harden and the handle is made from walnut pulled out of an abandoned house.

I make a lot of these particular knives. Anytime I see a bedframe in the trash, I pick it up and take it to my shop. Not all bedframes make good little knives but enough of them do so that it becomes worth my while to pick them up. It is through these little knives that I can explore and just be curious. I use whatever I have lying around the shop for the handles, or I try out ideas, or I just tinker around with no particular goal in mind to see what will happen. Sometimes nothing happens, but sometimes I can make something special that didn’t exist before I made it.

This creates a wonderful feeling that starts in my head, and goes through my arms and out my fingers, and keeps on going down my legs out my toes. I think you know this feeling. Perhaps you get this feeling when you read your books by Mr. Tolkien, or when you play Breath of the Wild. There’s always something good on the next page or just down the way- you only have to go looking for it. Even if you don’t find anything you might have made a new friend, or learned something about yourself, or your brothers and sisters. That is something special and should be celebrated- because sometimes the best party is the unexpected one.

As a grownup I sometimes forget that the unexpected and unknown can be good things- I started making knives to remind myself of this. It takes courage to be curious and explore and it’s important to remember that there’s a big world out there.

Some days I wake up and have no idea what the world will bring me so I try to approach most every day as an adventure. I spent a couple days each week of the past year helping your dad out at his work. One day I showed up and he told me we were going to stock the pond at your house with fish. We got in his truck and went to the farm supply store and your dad got something to the effect of a thousand minnows. That was a fun day, and you guys were all there. You never know what may happen if you don’t explore a bit. Thank you for sharing that adventure with me- your mom took this picture:

I hope you have a fantastic birthday and you keep reading and exploring!

The knife I made you begins with a piece of bedframe that I cut into smaller pieces:

I trace my design onto the steel:

Then it’s just a process of cutting it out- I have special tools for this.

I always try to have a couple of these going and I’m usually working on more than one at once-

Once I get the shape right, I grind the bevel in-

Then they go into the forge, a controlled fire that gets the steel very hot and hardens the blade. It gets so hard that sometimes it’s difficult to drill holes for the handle pins-

After that I use sandpaper to get the bevels nice and smooth. This helps the knife to cut better-

This one is blunted for you, so you can learn the feel and what it’s like to carry a knife-

Here is a piece of Black Walnut. It was pulled out of an abandoned house in North Carolina-

I cut two pieces of it and fit it to the knife. For a bit of color contrast, I use a bit of fiberglass computer board blanks that I rescued from a dumpster-

Now it is pinned and glued to the knife handle-

Here is where I shape it….

…..and shape it some more-

And now I sand it till it is shiny-

I made you a nice sheath for it so you can carry it around-

Knifemaking: on the grace given to us by our small friends, and Every Man Jack

“The mist across the window hides the lines,

But nothing hides the color of the lights that shine”

Joe Jackson- “Steppin’ Out”

Everyone has had terrible neighbors at some point. If someone tells you they haven’t had terrible neighbors, then it’s entirely possible they are the ones who are terrible. When I was growing up there was a family a few houses down who fell into the category of ‘bad neighbors’. They had a large and unruly German Shepherd with a proclivity for shitting in everyone’s yard with a reckless abandon. Their three kids would terrorize myself and my two brothers, and I would be remiss in not mentioning that we did a good amount of terrorizing ourselves. Perhaps in some sort of dysfunctional samsara we alternated in which house was precisely villain and victim.

There was one summer day when the oldest of the terrible neighbor brothers was doing a proper bit of terrorizing on my younger brother. He had been in some karate or taekwondo classes and was running through some katas on him. I ran to tell my mother and my mother, most likely exasperated from dealing with an entire summer of these sorts of shenanigans, told me to just go hit him with a stick. I went to the tool shed in our backyard and retrieved a crude gardening implement, with a five foot oak handle and a rusty steel fabrication on the end for digging up God-knows-what. I immediately found the oldest brother and hit him over the head, making sure the rusty steel bit was the first point of impact. Then I ran like hell.

Not more than ten minutes later there was a knock on the door of my parent house. The mother and the boy I had just brained were standing there. He was bleeding from the head and teary-eyed, but otherwise ok. Their mother was some sort of attorney in town and though I don’t know what her particular discipline was, I find it to be a small miracle that no charges were filed. Everybody ended up alright, and while the terrorizing did not stop, weaponized garden tools and pre-pubescent kung-fu no longer made an appearance. Eventually everybody got older and found better things to do, and eventually moved on to life and adulthood.

Almost three decades later I would find myself doing contract work for an event company, and one of the brothers from that family was the vendor relations manager and in charge of contracting crew. When I found out who it was that was hiring me I was mortified. I told him I was sorry for being such a shit and he just laughed and said he was an awful kid. I was always his first call for festivals and events, and he was my favorite person to work with. He eventually took another job out of state. He grew up into a real good guy and I miss working with him.

As a result of all of that, I have made a decided effort to be a quiet and unassuming neighbor.

…………

A few years ago my girlfriend and I had noticed an elderly black cat hanging out in her flower beds and her porch. In her neighborhood there were always half a dozen or so cats roaming around and we were never quite sure if they belonged to anyone or were just feral or stray. Oftentimes we could hear them fighting at night- they sounded like wildcats. None of them had collars or appeared to have homes. We thought her visitor was a stray and she certainly looked the part: slightly feral with colossal paws and claws, and a disheveled coarse coat like a saber-toothed tiger. She appeared to be going blind but managed to exist just fine. She would pop up every few days, then disappear for a couple weeks. It was always nice to see her.

It turns out she belonged to the people living a couple houses down. These people were also what you would call terrible neighbors. The main offender was a gentleman who wore not one but two ankle monitors- the kind the State uses to monitor people under house arrest. We called him Hot-Pants because every time we saw him he was wearing some of those super short soccer shorts. The police were a common presence at their house. There was one morning years ago, when my girlfriend left her house to take her children to school she found police cars blocking her driveway. Several officers were behind their car doors with weapons drawn pointed at toward the terrible neighbor’s house. Apparently Hot-Pants had gotten into a narcotic-fueled altercation and tried to set one of the women living there on fire, culminating in violent resistance when the authorities arrived.

They did have really good fireworks though. Every Fourth of July we’d sit on her porch and watch. These weren’t Roman candles or bottle rockets. They had the ones you’d see at baseball games, the big repeating ones launched from a mortar tube. Whenever they launched them we could feel the concussion three houses down. They must have had a police scanner because, from what I could tell, they never got caught. They’d be firing them off, one after another, and then all of a sudden they would stop. We’d hear what sounded like an angle grinder on metal piping. They were most likely destroying evidence. Ten minutes later two police cars would come by and we’d see them turn their lights on, and then leave after another five minutes. My girlfriend and I would sit on her porch drinking bourbon and watch all of this go down. These were some of my favorite Fourth of July’s.

Every couple weeks for the next several years we’d see the police there. One time, my girlfriend was sitting on her porch when she saw Hot-Pants in a minivan speeding down the street, with a woman clinging to the hood and beating on the windshield, all while shrieking like a banshee. While the terrible neighbors did tend toward the dramatic, most of the dysfunction manifested as late-night screaming matches, punctuated with relatively (to all the other the other dysfuntction at least) civil police visits.

After several years, the wild black kitty that apparently belonged to Hot-Pants moved onto my girlfriend’s porch full time. We were pretty sure the cat had gone completely blind by that point because she was always bumping into the furniture. I’m not sure what kind of stuff the cat was made of because she was still catching birds and making it through the cold winters that we get. My girlfriend started putting out food and water for her, and inadvertently started supporting an entire ecosystem. We’d see possums and raccoons at the food dish in the mornings and evenings, as well as Mockingjays, Cardinals, and Bluejays. Hot-pants would occasionally be walking down the road and would ask if he could have his cat back, to which my girlfriend would reply that the cat could leave anytime it wanted to. It never left.

…….

Once the pandemic hit, we started seeing a lot more of the neighborhood cats at the food bowl on my girlfriend’s porch. Honestly they had probably always been there but we just hadn’t noticed until lockdown and quarantine. Apparently Hot-Pants had five or six cats that he didn’t really feed or take care of. Among this group of cats there was a younger scrappy-looking orange kitty who started showing up more and more. He had a mangled little ear, and what looked like a little staph growth on his shoulder. He was a little fucked up and kind of skinny, but I really liked his spirit. Whenever I was there I could usually find him hiding in the flower beds. Though Hot-Pants said it was his cat, he moved onto my girlfriend’s porch with the old black kitty. I always looked forward to seeing him when I went to see my girlfriend.

Nearly all of my work had been cancelled. All of my music gigs, production work, and knife shows- all gone. The unemployment system in our state is a joke, and I never received any of the PUA money. I was still paying an ambulance bill, several ER bills, and a surgery center bill, and they could all give less than a fuck about a global pandemic and people just not being able to generate income. There were riots happening a block from where I live, complete with curfews, tear gas, and buildings being set on fire. It was a stressful time.

The only thing that hadn’t been cancelled was my part-time warehouse gig, which has always tided me over when the work I actually care about is slow, and whose federal withholding helps me take care of taxes on the knives. Anyone who works in warehousing and logistics will tell you that you are not going to be working with the best and the brightest. I spent most of the time I wasn’t working with idiots trying to figure out how to pay rent and not get sued by private medical companies. As a result I found myself cranky, resentful, and more than a little bit bitter. Everyone has been in their own little personal hell because of this debacle, save maybe Jeff Bezos and whoever is running Pfizer. I learned a long time ago that doing work that connects me to the world has always been part of my purpose, and that purpose was taken from me.

On top of this there was the virus itself. The biggest priority was staying healthy and Covid free so I could work and not get sued by private medical companies. My girlfriend and I don’t live together and we were trying to figure out what the best way to keep ourselves and the kids safe. There was a period of two to three weeks when we didn’t spend time together in person, just to see what was going to happen. I was usually sitting at home pissed off, or playing Witcher 3 (I developed a video game habit to keep me out of trouble.) About this time she starting subtly suggesting that maybe I might want to take the little fucked-up orange kitty home. She said it might be nice to have a little friend with me while we figured how to operate in this new virus-filled dumpster-fire world.

I told her no way. My little apartment is more workspace than living space and the cat would hate it and run away. Maybe he didn’t want to be inside. I told her I am a lot of things, but a nurturing caregiver is not one of them, and honestly I’m surprised she even lets me around her children. But she kept gently mentioning this kitty, and delicately placing the idea of me having a cat in my head. She told me I wasn’t working long days, or weekends, or going to the shop or making knives. She told me that maybe I had some space for this little fucked up kitty.

The smartest of women are able to do this- shepherding their partners to a decision of action, all while allowing their men to think it was their idea all along. I am not naive to this, but eventually I found I didn’t have a good reason to not bring this cat home. Even her kids told me to take him because we were so alike- we were both orange, slightly mangled, kind of diesel, and a bit cranky. So one Saturday I went to the pet store and got some kitty supplies with some of my stimulus money, and went and got the cat off her porch and took him home.

The first thing I did was set the cat carrier in front of the litter box. I took him out and set him in it. I told him this is where he would piss and shit and that was rule numero uno. No cat tinkle in the corners or little surprises on the floor. Then I took him and put him in front of his food, and told him he didn’t have to be hungry anymore. I set him on my bed and told him this was his bed too, and that he didn’t have to sleep in flower beds.

Then he went and hid in my closet for eight hours. This was probably a bit of a shock and perhaps a bit traumatizing, and I probably had less than a gentle touch. He eventually came out and settled in. I named him Jack Knife. Something simple but elegant, and with a story to tell. I called him Jack for short.

I had gotten him this super fancy raw freeze-dried gamebird cat food, because I’m pretty sure he had been eating rocks and dirt his whole life. He hated it, wouldn’t touch it. I went back and asked the guy at the pet store what to feed him and he said just to give him kitten chow. It’s not bad for cats, it just has more calories and nutrients but can lead to unhealthy weights in adults. He told me when he starts to put on weight, switch him to adult food. Man could this cat eat. I would wake up, put a scoop in his empty bowl, and go to work. I’d come home from work and his bowl would be empty, another scoop. I would get ready to go to bed and his bowl was empty again, another scoop. Every single day.

He wanted to eat whatever I was eating. He hadn’t even been home a week one night when I was having a cheeseburger. He wouldn’t leave me alone so I gave him a decent-sized chunk. He spent the next two hours throwing up all over the place and I spent the next two hours cleaning it up. Viking kitty or not, cooked and seasoned before probably wasn’t good for his digestion. You just don’t know what you don’t know.

For my birthday my girlfriend payed for his vet appointment to get shots and looked at. He wasn’t very old. The vet told me you can pretty accurately age a cat by their teeth, and Jack was only about eighteen months old. He had a small ulcerated growth on his shoulder from a tough kittenhood. The vet said it wasn’t bothering him but I could schedule an appointment to get it removed if it became an issue. The vet techs, young women in their mid to late twenties, told me he was the absolute sweetest guy. I found it amazing that a creature could have such a brutal beginning and yet allow himself to feel safe and cared for. No bitterness, no resentment, just love. I was his person, and he was my little friend during a very lonely and uncertain time.

About this time I got really into making spaghetti bolognese, with pancetta, ground pork, and veal when I could afford it. You deglaze everything with a dry white wine and finish it with heavy cream. I would give him some of the sauce in a little dish. He always purred when he ate, always. He just wanted to eat, sleep and snuggle.

Jack eased the loneliness and existential anxiety that came from the torrid state of the worlds. I would come home from whatever stupid job I had been doing that day and he would be sitting on my coffee table waiting for me. He would follow me around until I sat down and then he would climb onto me and fall asleep while I played Nintendo. I would talk to him while I worked on the very occasional knife commission I would get. He was a terrible knife maker.

He was a quiet guy, never really meowed, didn’t claw anything, and didn’t ever bite. He did particularly enjoy knocking my water glass off my nightstand, watching satisfied as glass bits and water went all over the place. He would never run away afterward- no shame in that one. I would just clean up the glass, mop up the water, and fill up his food bowl (which was perpetually empty despite my best efforts.) I lost half a dozen glasses.

For a good three weeks, I was really into making sandwiches. I would make a quickie aeoli, and use the aged smoked cheddar that they sold at Aldi. I would always give Jack a bit of the cold cuts as I was making these breaded works of art to take to work, or for dinner. Even when I got tired of artisan sandwiches and moved on to other things, Jack thought that every time I went into the kitchen I was making sandwiches and he wouldn’t leave till he got his cold cuts. So I always kept some in the fridge.

I started noticing that Jack was getting a little bit lethargic and reclusive. I called the vet to get his small growth removed, and scheduled his procedure. I felt a little guilty about not doing it sooner, but he was a tough little alley cat, and I always tried to let him be. I had gotten my second stimulus so I scheduled his procedure for the same day i got my Covid vaccine.

The vet said he did really well and he just needed to rest and take it easy, which is what he usually did anyway. I picked him up and took him home and kept an eye on him for a few days. He was not getting better. His surgery wound was great- clean, dry, and healthy. He was hiding in my closet most of the time, and one evening I found him sleeping in his litter box, which Google told me was usually the sign of a very sick kitty. The next morning I noticed some swelling in his little face. I was afraid he had an abscess in his tooth and I made an appointment with my vet to have a look at him the next day.

I got home from work that evening and he was having trouble breathing. His front legs had started to swell and he was lying on my kitchen floor. I was really hoping to make it through the night to get to my vet, whom I just love, but around 11p I gave him some cold cuts and took him to the emergency vet.

I think it goes without saying that nothing pleasant happens at an emergency vet clinic at 11p on a Wednesday evening. As I was standing in line a lady was filling out a ‘do not resuscitate’ form for her dog in surgery. When they took Jack back I sat down to wait and I could hear a lady sobbing uncontrollably in one of the exam rooms.

When they called me back to the exam room it was not good. Cancer had ripped through his little body and the vet told me he was more than likely sick even before I took him home from my girlfriend’s flower bed. The reality was, the vet told me, was that he was probably just looking for a safe place to lie down. He was also anemic, which was why he could eat so much and didn’t really gain any weight. I asked the vet if I fucked up somewhere along the line and she said no, sometimes life is just incredibly brutal for outdoor cats. She also said it was probably good I didn’t get his little growth removed sooner, because the trauma of that procedure most likely exacerbated his illness. I asked if he was hurting and the vet said no, he was just uncomfortable but there wasn’t anything that could really be done for him. She told me in so many words that Jack would not live to be an old cat and I just sort of lost it.

It sounds really silly to say because most everybody I know, including myself, lost big things during those years. Time, people, relationships, careers, opportunities- things that are just gone and can’t be gotten back. But living under the backdrop of chaos, duress, and uncertainty for an extended time can leave us a bit fragile and worn out. Things that might have been an emotional inconvenience at worst suddenly loom large. This was one such instance: in a lonely little exam room at two in the morning where nothing good happens, we put Jack to sleep.

The silver lining of shithead neighbors and devastating pandemics is that you can find big things in the smallest of places. In spite of everything that little cat was loving and sweet till the very end, and a good friend. If that isn’t grace, then I don’t know what is. I sure do miss that little guy.

Hand sanding before the forge:

Hand sanding after the forge:

These are some cedar shavings soaked in fiberglass resin. They will clean up nicely:

All material ready for glue up. Computer board spacers and homebrewed dungaree micarta:

Glued up:

Shaped up:

Shaped up:

The Every Man Jack:

Knifemaking: remembering the magic, and the Bounty Hunter

“Come On, Baby! Do The Magic Hand Thing!”

-Greef Karga, from “The Mandalorian

I remember, at the age of fourteen, running around my grandmother’s backyard and pretending to have a lightsaber and desperately attempting to feel the Force flowing through me. It was around 1998 or 1999, and I had just seen the special edition of “Return of the Jedi”. Other fourteen year-olds I knew were busy with sports, or having girlfriends, or smoking cigarettes, drinking, or doing drugs. In other words, doing nearly anything but pantomiming a nearly fifteen-year-old sci-fi-fantasy film in a relative’s backyard, but there I was. By that point I had been neck deep in the lore of Star Wars for years. I had all the books- from the Jedi Academy series and Tales of the Bounty Hunters, to the books detailing the technical specifications of the weapons, technology, vehicles, and alien races. I played Dark Forces and Dark Forces II: Jedi Knight, Jedi Knight II, Shadows of the Empire, and half a dozen others. I knew the legacies of Dash Rendar, Kyle Katarn, and how to make a Ruby Bliel. I had the soundtrack to all three films, each on double cassette. I hadn’t tasted the kool-aid: I had dove headfirst into a vat of the stuff.

What this type of fixation does in younger people, as any nerd-dom member will tell you, is allows one to cultivate a rich inner life and vivid imagination for things. It also teaches one to see the magic where one would not normally expect to see it. This is why many nerds grow up to be incredibly interesting and capable adults.

On top of this, everyone experiences times when they find it difficult to see the magic in life. Falling down rabbit holes teaches you how to nurture yourself when everything might not be so inspiring. The thing that has always saved me is remembering what it is to feel the mystery of it all. The past year has been an exercise in this. Most of my work has been cancelled due to Covid and as of yet has not come back. No knife shows, no gigs, minimal commissions. One of the bright spots of this whole debacle has been season two of the Mandalorian in the fall and winter of 2020. When you’ve been stuck at home doing menial pandemic work just trying to pay the bills, there are few things like a person of a mysterious creed and badass armor having interstellar adventures with Carl Weathers and Bill Burr and a Force-sensitive baby Yoda. Every week I tuned in like I was fourteen. It’s deeply reassuring to know that during such troubled times there are things to make you remember why you pursue that which you value and help you to feel the magic in everything.

For me this is the beauty of having a small custom knife shop. You can do anything you like. There are limitations, the greatest being time, but almost anything that you can think of you can usually do (provided you have the patience.) In this respect, it’s important to keep the mind limber and receptive to creativity for when the muse strikes us. If I am not inspired, I know how to find those things because I’ve been doing it since I was little. Sometimes it’s podcasts, or a song, or a line from a book, or perhaps even a conversation or something I’ve eaten. Because of the pandemic and not going out into the world in my accustomed fashion, this has been quite challenging most days. If I can stir myself, then i can certainly stir someone with a knife I’ve built. If I’ve done that, then my job is complete.

But sometimes we get commissions where WE are the ones who get stirred. We prefer to do everything in house and make sure the work comes from our own hand. While we don’t outsource tasks very often, occasionally we’ll get a commission that is interesting to us and requires that we do so. I received and email from a very good customer asking if I could get a Mythasaur skull on a custom blade and sheath. I thought of how the Mandalorian was such an oasis during a tough time; my own personal magic-hand-thing. I came up with a design that I hoped could fit a Mandalorian bounty hunter and found a laser engraving company in town. Chase your muse, do the work, and walk your path, don’t give up. It’s a journey but this is the way.

A quick schematic
Roughing out the profile
Removing a bit of weight and putting in rivet holes
Properly profiled
Bevels ground in
Pre-heat treat sanding
Out of the quench and cooling
Beginnings of a satin finish
…and we’re there.
A technical schematic for the laser people: precision is the name of the game.
Proofs showing how the engraving will look- the blue is for contrast.
And it came out just like the picture
The handle is made from a pair of Carhartt Dungarees I got too fat for….
Cut into strips….
…layered into strips….
…with the resin…
And this is the raw material, about 3/16″ to 1/4″ thick.
A PCB filler blank, rescued from a dumpster.
Everything gets drilled and glued/riveted together.
Ready for shaping.
Profiled
Shaped to fit the hand. This is off the grinder at 60 grit. The rest will be done by hand to help the material speak.
At around 120 grit you can see the “grain” start to speak. The higher you polish it, the more pronounced it will be.
The Bounty Hunter

Knifemaking: on the power of curiousity, and The Esperto Universale

Some may have, and some may not
God, I’m thankful for what I got

Warren Zevon- “Hasten Down the Wind”

Ever since I was a little boy, I was always interested in people who did things. Everyone likes to ask children what they want to be when they grew up, but when asked I never really had an answer. I always wanted to know how to do things and why things worked the way they did. I use to spend hours in the how-to section of the library, and record songs I liked off the radio to cassettes. I’d listen to them over and over again to see if I could figure out what made them move me so, all the while wondering how the person who wrote it pulled it out of themselves. For hours and hours I would listen. To nurture this, I was given painting and music lessons. As I got older, though I couldn’t have articulated it at the time, I realized I wanted to be a professional doer-of-things. Unfortunately, there is no specific vocation for that, no box that school guidance counselors can check off or program that they can put you in. I did my best to fit in and do as well as I could in school. School administrators want to see you be a productive member of society and we were all nudged toward that goal, but it all felt boring to me.

Fortunately the curious parts of me were nurtured by band directors, private music instructors, and Boy Scout leaders. I studied jazz and dissected chord changes and figured out what made things sound the way they did. I played in concert bands, jazz groups, and marching band. If it weren’t for marching band I never would have had any dates to school dances. On the weekends I’d go on camping trips and figure out different ways to set things on fire with a bunch of other wild ass kids. In the summer I would go to the local camp and sail boats, shoot guns, practice archery, and continue to set things on fire.

When most kids were saving up for beach week, I bought a Tascam 414 MkII four track cassette recorder. I taught myself guitar and wrote songs in a seven member rock outfit with metalheads, grungers, and punk rockers. Over the years we would play battle of the bands and anywhere that would have us. We rocked middle school dances like nobody’s business.

I went to college and studied music. In the summers I built commercial cabinets in a cabinet shop and tiled kitchens and bathroom working an apartment maintenance gig. Technically these could qualify as shit jobs but I really enjoyed seeing a re-done bathroom that was made nice by my own hands, or driving by a high-powered lawyer’s office and knowing I built all their reception desks. It’s empowering to know that it’s within your power to make beautiful things.

I graduated from college just shy of the 2008 financial collapse. I had figured I would land in some sort of interesting vocation and somebody would just hand me a bag of money, but the country was a wasteland for anyone getting out into the world at that time. People were losing everything they had worked for and the system couldn’t give less of a fuck about a whole batch of college grads who were ready and willing to be functioning members of society. Everything I had heard growing up about the metrics of success turned out to be out of sync with what the world was becoming. Suffice to say expectations were non-existent. I decided I would just continue to do things that I found interesting. If I was going to be poor, I might as well do the things that spoke to me.

I worked just about everything that seemed interesting. When you’re curious about things you tend to say yes to things that come your way. I played gigs and wrote and arranged music. I worked in operations for the local symphony, ballet, and various concert venues or arenas. I was a shipping clerk for a hot minute, a summer camp head of resident life, and managed a warehouse for an auction house. I don’t think I’ve ever been bored and met a lot of other curious people who had appreciation for the mystery of it all. People that you would call renaissance men (or women), who were off the beaten path. Universal spirits who understand the magic that comes from being curious and chasing the muse.

The Esperto Universale was built for one such man I met a few years ago. I was at a friend’s farm for thanksgiving, a potter and musician and overall curious man. He had some of his friends over who were also curious and interesting people. I struck up a conversation with a gentleman about working for Taylor Swift’s Red tour- it turns out he had built the steampunk piano for her show. He was neighbors with Michael McDonald and played porch concerts with him. He and his wife founded the Blackberry Jam Music Festival in Tennessee and perform on it as well. He’s also an inventor and has patents on products you can get at Home Depot.

There’s no roadmap for anything in this life and while I am use to being the odd man out in most situations, it’s always reassuring to meet others that have made being off the beaten path a successful lifestyle. In a brutal world, these sorts of souls you meet along the way help you to feel me connected and seen.

This knife was commissioned by his loving wife. This gentleman is a woodworker and musician, among other things, so I used some reclaimed Cherrywood that came off an old mantlepiece. The bolster is a micarta made from black jeans that I used to wear for a weekly big band gig. Something one of a kind for a unique man.

A quick sketch,
Profiled in O1 Tool Steel.
Refining the profile.
Ready to grind the bevels.
Bevels ground. The drawing showed a swedge, but that was out of concern that the tip would be too thick. The knife ended up not needing it.
Removing the rough machine marks by hand before heat treatment
Final profiling before hardening
After the quench.
Tempered to remove stress from the steel after tempering.
Satin finish.
Gig pants to be cut up and layered in fiberglass resin.
The raw material.
Furniture grade Cherry.
Bookmatched.
PCB board from network chassis. Rescued from a dumpster.
Finishing the handle.
The Esperto Universale

The Esperto Universale is made of high carbon steel, which means it will take a keen edge, hold it a good while, and will be easy to sharpen. It will stain and patina and tell the stories of the places you’ve been- this natural and characteristic of the steel. Your knife is made to be used so don’t be shy about getting it dirty. Be sure to keep your knife clean and oiled when not in use. Should you find any unpleasant surface oxidization you can remove it easily with a lightly oiled bit of 0000 steel wool, or a coarse rag with a bit vinegar on it.

The Blackberry Jam Festival

Knifemaking: on being part of a team, and Puttin’ on the Fritz

“No member of a crew is praised for the rugged individuality of his rowing.”
― Ralph Waldo Emerson

For the past thirteen years I’ve worked off and on in the operations department for the symphony orchestra we have in town.  What many people may not be aware of is that there are a lot of logistical factors and people involved in getting an 80-person orchestra on stage to perform Beethoven: more so to perform Ravel.  Risers need to be built and installed, specialized percussion needs to be rented or even custom made, guest artists need to be booked and accommodated.  None of this even includes the years of training on the part of the musicians, or the planning and learning of the repertoire.  Outside of this, there is a whole team of people running youth programs and community choruses, each with their own logistical needs.  As one can imagine, it is tremendously expensive to run an orchestra and a great many people work very hard so that the classics can be heard as they were meant to be heard.  In a complicated and difficult world, it’s deeply comforting to know that there are people working tirelessly with sole intent of putting good work out into the world.

In recent years, however, people haven’t been going to orchestra concerts as they have in the past.  All over the country, symphonies have been closing down.

A few years ago a decision was made by the upper administration of the symphony in town to invest in a mobile tent big enough to put a stage and orchestra under.  This would allow the orchestra to be mobile and to perform concerts anywhere.  With the community just not going to the symphony as it once did, it was decided that the symphony would go to the community.

A large tent was purchased from a Canadian company and staging from a different company.  Two 24-foot box trucks were purchased to carry around the tent and stage, as well as all the accoutrements necessary for construction: wrenches and sockets, a jackhammer named Petunia, stake pullers, sledgehammers, a laser leveling system, and several tons of trusses, scaffolding, and hardware.

A crack team of theatre and stage professionals was assembled for crew.  At the helm of this endeavor was a husband-and-wife team, the Operations Manager and Production Manager of the Orchestra, who oversaw everything from site surveying to maintenance of the trucks to making sure everybody got paid. The assembled crew included a gentleman from the IATSE Local 87, who was an ace electrician, lighting operator, and rigger.  There was also a gentleman who was the technical director of a university-run theatre and a deus ex machina of lighting design, sound, carpentry, and all aspects of building and running a production.  Then there was a gentleman who did sound and logistical transport on motion picture and television sets for the Teamsters, and another gentleman, a math whiz working in IT and a veteran stagehand and crewperson. Finally there was me, a generally nice guy who always showed up on time and happened to be extremely proficient at moving heavy things. More people would come over the years but this is what it started with.

At some point or another I had worked with all of these people extensively, or helped them move, or gone to happy hour and had one or ten drinks with them.  As this project was getting started, I found myself really happy to be working with proper criminals of the theatre and entertainment industry.

A weekend was booked for training on how to put the tent up. The owner of the tent company came down to train us on how to put it up and take it down. He was a Canadian septuagenarian, who was formally an engineer for a railroad company in Winnipeg. I’m not sure how much the tent cost but it must have been significant for the elderly owner to fly down from Canada. As it turns out he wasn’t as elderly as he looked. We set it up and took it down twice.

As with any large task, the crux of the build was built on many tiny steps. Permits for a temporary building structure are obtained for whatever county the performance is happening in. The site is scouted and surveyed, locating the flattest area possible. Locations for the load-bearing stakes are marked out according to the tent schematics. There is a single truck that contains all the parts and pieces for the tent- trusses, skins, poles, spansets, straps, stakes, the lot. Building it involved doing each of those tiny steps really well, and in the proper order. At first it was overwhelming.

Photo credit Tim Posey

What makes this job different from a theatre or arena is that everybody pretty much knows how to do everything. No job is more important than another and we were trained to be able to do it all. With the exception of driving the trucks, which requires a CDL due to weight, or operating the Lowell boom lift, which is an issue of insurance, anybody can jump on wherever there are tasks to be done. We all hang the lights and wire them up. We all move everything and everybody tightens bolts, hammers in stakes, and skins the frame. In the hierarchy of the job we always defer to the crew chief, but there is a level of trust that comes from having worked with everyone on a plethora of different jobs over many years. In this line of work there is an Esprit de Corps that is hard to explain to anyone who isn’t in the industry. We can put this thing up in our sleep and feel confident that the job was executed to the highest standards. If someone misses something there are at least three other guys (or gals) there to catch them.

While everyone can do everything, over the years we’ve all settled into leadership specialties within the scope of the job. There are two gentleman handle the business of getting the tent in the air, and everyone else knows to fall in to take orders. There are two other gentleman who take the helm of leveling the scaffolding for the massive stage that goes in the tent. I found myself managing the loading and unloading the stage truck which involves about fifteen tons of decking, railing and step units- everything having to be unloaded by hand. One gentleman is really good at getting the tension on the support lines really dialed in, giving the tent it’s sleek look.

Photo credit Tim Posey
Photo credit Tim Posey

It’s a good feeling to know that you were part of a crack team of professionals making something special happen. There aren’t any corporate teambuilding exercises or classes that comes anywhere close to making live entertainment productions happen.

Photo credit Dave Parrish Photography

Not everything goes according to plan and training isn’t going to prepare you for every contingency that is bound to happen. There was one time we had to drive all of the four foot stakes by hand when the hardened metal stake driver tip on Petunia the Jackhammer shattered. It took forever and put us behind. We have loaded everything wet in the pouring rain before and it is deeply miserable. Sometimes the industrial grade rental generator shows up late and we have no power till it gets there.

I was riding to an out of town tent gig with a couple of the guys. We were on the interstate and I saw the freshly-removed tread of a truck tire in the middle of the right-hand lane. “Somebody’s having a bad day,” I thought to myself. About three minutes later we passed one of our trucks on the side of the road, with our driver on his phone besides, and a bald rear exterior tire. Ahh, we were the ones having a bad day. So everybody gets on their phone to figure out who we can get out there to change the tire on a truck loaded with 20,000lbs of gear at 7am on a Saturday morning. We had to rent a Uhual to start getting tent trusses to the site so we could get started. We didn’t get our truck tire fixed till noon because the lugs were so rusted that they were frozen to the bolts.

Blowing tires is a pain but it doesn’t happen too often. The biggest single pain is when the trucks get stuck and it happens all the time. Usually we know when the ground is saturated and we can lay out a track of plywood decking. We have to move them Egyptian-style as the truck moves and it is exhausting but a huge time saver. One time our stage truck got stuck so badly we had to call the biggest wrecker I have ever seen to pull it out. Then the wrecker got stuck. There was a season where the truck got stuck almost every other job and sometimes there just any other way around it.

Leveling the truck to the stage: the shims also make it easier for the truck to pull off without spinning into the ground.

Note the truck in the top left corner with front wheel buried to the rim in soft ground
Photo credit Tim Posey

Puttin’ on the Fritz was commissioned by an old friend of mine that I went to music school with. It was built for his brother, a member of the Army Special Forces. My friend and I have worked in similar industries where teamwork at a high level is essential, and this is no doubt the case for his brother. I designed a beefy fighting/utility knife with a harpoon point and a hardened skullcrusher on the butt of the blade. “Puttin’ on the Fritz” is a nod to the things that go wrong, and how we respond to them. It’s not a matter of if but when. Having a really good team helps you to accomplish things bigger than yourself and move through the adversities.

A quick sketch
Roughing out the profile
Profile dialed in.
That scribed line will become the final cutting edge.
Bevels are ground in.
Removing the machine marks.
Hardening- this is almost hot enough.
A little blurry after tempering
Laying down a satin finish.
600 grit
Skullcrusher
An old pair of work dungarees
Cutting the material for layering
These pieces will be layered in fiberglass resin.
Ready to be smashed together.
The raw material.
PCB fiberglass from a computer board blank that was rescued from a dumpster.
220 grit.
1000 grit.
Ready to be riveted and glued.
Clamped.
Ready to shaped
Ready to be contoured
Contoured
This is polished to 120 grit. The higher the grit you go, the more the material speaks.
Etching in the maker’s mark
Puttin’ on the Fritz

Puttin’ on the Fritz is made of high carbon steel, which means it will take a keen edge, hold it a good while, and will be easy to sharpen. It will stain and patina and tell the stories of the places you’ve been- this natural and characteristic of the steel. It came to you coated in EEZox gun oil, an oil based film that protects the finish. Your knife is made to be used so don’t be shy about getting it dirty. Be sure to keep your knife clean and oiled when not in use. Should you find any unpleasant surface oxidization you can remove it easily with a lightly oiled bit of 0000 steel wool, or a coarse rag with a bit vinegar on it.

Knifemaking: on hitting your mark, and The Crack Shot

“Each arrow leaves a memory in your heart, and it is the sum of those memories that will make you shoot better and better.”

Paulo Coelho- The Archer

A few years ago I went to go see a modern dance piece with my girlfriend. It was called “Tensegrity” and was based on the idea of tension in cells: wherein the structure of the cell is maintained through continuous tension in some of it’s supports and continuous compression in others. When any one of those tensions or compressions are interrupted the cell falls apart, or at least that’s my understanding of it. This idea has been around since the 1960’s, and is a portmanteau of “tensile” and “integrity”. These days the idea is used a lot in contemporary architecture and to make coffee tables and other furniture. There are loads of these tensegrity tables and sculptures on Pinterest, but the first I had ever heard of this was at that performance.

The choreographer of this piece is a good friend of of ours and after the performance we went to get a drink with him. I’ve always admired how prolific he is, constantly moving from piece to piece, work to work, and the way each performance had it’s own voice and character. I was a bit stuck at the time and was curious how this man could take shot after shot and always hit his target. So I asked him.

He told me that whatever you do, you have to do a lot of it, and sometimes badly. Everything is connected, he told me, and each piece builds off what you have done before and is fed by your collective experience. Always keep going, and always be thinking of what’s next. At least I think that’s what he said; a fairly liberal number of martinis and fireball shots were consumed and things started to get a little fuzzy…

Over the years I’ve thought about that night, and how seemingly incongruous disciplines fit together to propel a skill or craft forward. You hear about football players taking ballet but I met an orthopedic surgeon who was an ace pickle maker, and one of my favorite knifemakers is an avid botanist. So when you find choreographers exploring contemporary cell biology or bowhunters dabbling in Vipisanna meditation, you will probably find that they are drawing connections that are deepening and balancing something. Whenever I talk to people who are really good at what they do, I find there is an ocean of eclectic and varied experiences just beneath the veneer of whatever it is they practice that adds something special to their work. The sum of our experiences can always help us hit our mark.

The Crack Shot is a nod to this idea that the sum of our experiences can always help us hit our mark. It was built for a hunter and a woodsman. “Crack Shot” is an homage to his grandfather, the original Crack Shot, who taught him about being with nature, shooting, and how to hit your mark. It is the intention of this knife, with it’s blend of handmade and reclaimed material, to help it’s recipient remember the man who helped him be where he is today.

A quick sketch
Roughing out the profile
Grinding in the bevels and swedges. Since this is thick stock, the swedge will make a finer point for piercing.
Removing the machine grinds by hand. This will make polishing easier after heat treatment.
Almost there…
Post-quench cooling.
After tempering- note the faint straw colors. This has drawn much of the stress out of the blade that built up during quench, making it much more durable.
Hand sanding….
…to a nice satin.
Etching in the namesake.
The client wanted something masculine and woodsy. I find there are few things more timeless that flannel and denim.
Alternating layers, so each piece should form a grain and be able to speak more articulately.
Prepped.
Each layer of clothes is smothered in fiberglass resin.
Now to smach everything together.
This is the raw material. All the layer have been permeated with resin, making everything a solid block.
Cutting out the bolsters.
Drill rivet holes.
A rough mockup so I know how everything fits together.
This gets sanded before glue up. I won’t be able to get to this part after everything is glued and riveted together.
All sanded up.
A piece of block walnut. I was doing tree work at an artist’s house in Charlotte Court House, Virginia. He had loads of this stuff. It was milled by his neighbor, a retired parishioner who started an abbey in South Korea in the late 1990’s to help North Korean defectors acclimate to a free country. It is very beautiful wood.
Bookmatched.
A fiberglass PCB blank for a network chassis full of hardware that runs your internet. This was rescued from a dumpster.
All laid out and everything fits together.
Two-ton epoxy resin.
Clamped.
Now for shaping.
The Crack Shot.

The Crack Shot is made of high carbon steel, which means it will take a keen edge, hold it a good while, and will be easy to sharpen. It will stain and patina and tell the stories of the places you’ve been- this natural and characteristic of the steel. Your knife is made to be used so don’t be shy about getting it dirty. Be sure to keep your knife clean and oiled when not in use. Should you find any unpleasant surface oxidization you can remove it easily with a lightly oiled bit of 0000 steel wool, or a coarse rag with a bit vinegar on it.

Some further reading on cellular tensegrity referenced in the text body above:

Constructing Tensegrity Structures From One-Bar Elementary Cells

Knifemaking: what we do with the unexpected, and the Foundling

“I was once a Foundling.”

Din Djarin, from The Mandalorian

A few years ago I got a call from a gentleman about a knife that needed a new handle. He had a thick Australian accent and told me one of his friends was redoing some walls and ceilings in her house and had found an old cleaver behind the drywall. He asked if I would be able to put a new handle on it, and by the way it was also going to be a wedding present for his friend who found it.

A mysterious butcher’s tool in the walls? A wedding gift? Nuptials without knives are nuptials not worth having. Besides that, certain things in life have a habit of being found when we need them the most. This all sounded extraordinarily auspicious to me. Of course I took the job. I couldn’t have made this up if I tried.

I met my new Australian friend, who at the time was raising Alpacas (because of course he was), at a country bazaar just outside the city and picked up the cleaver. It was important to me to honor the found-nature of this deeply immodest blade of humble origins, so all the material save for the pin stock and adhesives came from refuse dumpsters or abandoned houses. I named the cleaver Wallace, and returned him to my Australian Alpaca friend. As with any other job I dropped the work off, made sure the person paying me was happy, and didn’t think much of it.

I did finally met the lady who found the cleaver at one of our shows, and she has bought a knife almost every year around Christmas time. She got in touch this year about having a knife made, and I realized that her and her husband had never seen how the cleaver was built.

I think the things that find their way into our lives are so much more interesting than the things we seek out. While it’s good to have a plan, it’s also important to acknowledge that plans fail, often spectacularly, and the best things happen to us while we’re planning something else. We stumble into to deep love, or fall into a career, and despite our best calculations, the special moments and deepest connections in our lives seem to occur solely at the whims of the universe. Very much like Wallace the Cleaver and his handle made from garbage that somehow found it’s way into our shop, it’s up to us to choose what to do with the things we find ourself with.

The Foundling was a commission for her husband, who was always stealing her knife, and was built using all sorts of materials that found their way to me.

The Foundling starts with a quick sketch
The scribe lines show where the final cutting edge will be
Jimping is filed in on the spine for grip
The grind at the top of the spine is called a swedge, and give the blade more of a point
Wet sanding before hardening
Into the forge
After the quench
…and after tempering
More polishing
A quick etch in acid
A piece of Cherry wood, which came off an old mantlepiece
A PCB blank, rescued from a dumpster
A piece of copper plumbing pipe

Knifemaking: softening and connection; and the Gun Dog

“How we fall into grace. You can’t work or earn your way into it. You just fall. It lies below, it lies beyond. It comes to you, unbidden.”
― Rick BassColter: The True Story of the Best Dog I Ever Had

I wouldn’t have ever really considered myself a dog person, not really. There is an appreciation and respect for all animals, both wild and domesticated, and whatever creature I meet I try to let them know that I see them- a deep namaste and acknowledgement of being. But as far “being a dog person”… I’m just not sure I have whatever that is.

A couple of years ago my girlfriend said she was thinking about getting a dog. I told her don’t do it. My only reasoning was that we were all very busy doing interesting and challenging work, her kids were getting older and doing more things, and everyone was tired all the time. I figured it would probably be best if we held onto every ounce of emotional energy that we could.

In spite of my reasons, which themselves came from a lovingly practical and pragmatic place, she did not listen to me. This lady is one of the most unfailingly capable people I know, a wonderful mother, with the uncanny ability to make everything around her better than it was before, even on her worst days. It was no surprise when she brought home a several-month-old rescue puppy. This dog was a lemon drop beagle mix with the biggest ears I’d ever seen. She seemed to be equal parts fruit bat, luck dragon, and polar bear.

The local animal league had told my girlfriend that this dog and her sister had been found abandoned in a barn. The puppy’s sister had some sort of severe muscular dysplasia and had found a home. My girlfriend’s puppy had a little bit of this, but much less so. She moved around fine but a closer look showed her front half didn’t quite work together with her back half.

When I met her she was still adjusting to her new home. She was terrified of doorways and dinner plates. She didn’t want to leave whatever room she was in and when she did she scuttled through like something was going to get her. If you were to put down a plate of puppy chow in front of her she would back away as if it were going to bite her. In spite of all of this she was a deeply loving and affectionate dog which was amazing considering the shit sandwich of a beginning she had been given. At that moment, shortly after meeting this dog, I felt something soften toward this wonky little barn dog that was part fruit bat, luck dragon, and polar bear; this sweet little creature that I told my girlfriend not to get.

Over the next few years I would tell this dog that I was sorry I told her mom not to get her. She had grown into a rather stunning animal, and her front half worked together much better with her back half. Doorways weren’t too much of a problem though her old nemesis the dinner plate still gave her pause. I found myself very attached to her and, though she was very much a lady dog and a product of my girlfriend’s deep nurture, I would find her to be the loving presence that I didn’t know I needed. The dog just loved everybody.

A couple of years ago I had a table saw accident that left me needing reconstructive hand surgery. It was incredibly stressful and emotionally grueling. All of my work and projects and everything I was so busy with would come grinding to a halt for the next few months. My girlfriend moved me into her house for a week and took time off work- thankfully the kids were away at summer camp. My girlfriend’s dog never really left my side. I remember the dog licking my gimpy hand every so often and then pressing in to me and going to sleep, which prompted me go to sleep. I don’t remember much of that week, except my girlfriend smiling and her really sweet dog. It sounds really silly, and perhaps it was the massive amount of post-op hyrdromorphone I was prescribed, but I figured I should probably take the example of the dog that I told my girlfriend not to get and find a way to dig in a little deeper with her and the kids.

Connection can be a struggle and there’s no manual on the right way to go about it. Sometimes it takes a sweet dog after a traumatic event to help you see what you should be doing. Part fruit bat, part luck dragon, part polar bear (everybody is good and healthy, including my hand and the dog I told my girlfriend not to get). If a responsible adult in your life tells you they want a dog, you should tell them to go right ahead.

This knife was commissioned for a retired gentlemen who trains English Setters for hunting. Hunting Dogs, or Gun Dogs as they are called have been around for centuries. Particularly, the training of Setters can be traced back to Robert Dudley, the Earl of Leicester in the 1500’s. It was commissioned by a loving daughter, and has “Pop Pop” etched on the flat of the blade from his grandchildren.

A quick sketch.
Removing material in the handle make for a more balanced blade.
Everything profiled out. Being that it is made from thinner stock, it will go in the forge as is to prevent warping during hardening.
The blade needs to come to critical temperature, which is around 1500F. By the colors you can see that it is almost there.
After the quench. There wasn’t warpage but I still clamp it in the vise at the areas where it would typically bend. When it comes out of the oil it is around 300-400F, and during this time any major warps can be corrected before it cools.
The bevels have been ground in and machine finished to 120 grit.
This has been hand sanded up to 600 grit, finishing with vertical pulls. This will get etched in acid to provide a scaffold for the patina to build, and also give it a more rustic look.
Electro-chemical etching using nail polish, some salted vinegar and a nine volt battery with some alligator clips. This allows me to essentially burn text onto the steel.
A pair of Carthartt work dungarees, probably about 10 years old.

Instructions for Care:

 Your knife is made of high carbon steel, which means it will take a keen edge, hold it a good while, and will be easy to sharpen.  It has been etched in acid and shipped to you coated in food safe mineral oil. It will stain and patina and tell the stories of the places you’ve been.  Be sure to keep your knife clean and oiled when not in use.  Should you find any unpleasant surface oxidization you can remove it easily with a lightly oiled bit of 0000 steel wool, or a coarse rag with a bit vinegar on it.  She is built to be used, so don’t be shy about getting her dirty.

You can read more about Gun Dogs here, as well as find more resources on this very old tradition