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: 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

Knifemaking: a commencement address (of sorts), and the Masilda

Dear Younger Person Whom I’ve Never Met Before:

Some very dear friends of mine asked me to make a knife for you.  These friends of mine are wonderful people that I have known for quite some time, and shared many adventures. They told me they have known your parents for a long time as well, so I can infer that your parents are wonderful people too. They have also known you since you were born and, if I may be so bold, I can only assume that you are a wonderful person as well, and that we are well met.

I was also told you have completed your secondary studies and are going out into the world- congratulations! My very dear friends asked me to make you something special, but also something that was functional and practical.  Something that would serve you well on outdoor adventures; an elegant tool and faithful companion.  Something to remind you of where you have grown up.  A security blanket that doubles as a prayer rosary and, if I may say so, a bold fashion statement.

As you may have noticed, Younger-Person-Whom-I’ve-Never-Met-Before, the situation of the world is a bit spicier than usual.  To be honest, the only thing that has gotten me out of the house most days in this great year of 2020 is knowing that I will be coming back home as soon as possible.  In spite of my trepidations of late, I’ve found that time marches on and life stops for no one, and there’s no point in staying home and being afraid while life passes you by.  The world cares not for our anxieties, worries, or fears, Younger-Person-Whom-I’ve-Never-Met-Before, and the sooner this is understood the freer we become.  Be sure to wear a mask, practice social distancing, and listen to the experts.  That is what they are here for.

I have designed and built you a bushcraft knife.  She is made from 1095 hi-carbon steel, which has been differentially hardened.  What this means is, while the whole blade is hardened, the cutting edge is the only part of the blade at full hardness and the spine is just slightly softer.  This offers durability and a slight bit of give, like a samurai sword.  There is a smoky line along the edge of the blade and a slight color change where you can see the differences in hardness.

The handle contains a piece of bookmatched Texas Mesquite.  It comes from a cousin of mine near Big Springs, milled on his property.  The bolster is made from a pair of lady jeans that belonged to my girlfriend- vintage Levi’s 501’s, something strong and deeply feminine.  Your knife is stout and sturdy; strong enough to baton firewood but lithe enough to prepare dinner. 

I named her Masilda, which is an old Romany-Traveller name that means ‘battle-ready’.  And while I am no authority on anything, your knife does contain a few truths and values in which I strongly believe.  Having a knife named battle-ready is no empty moniker and I have consolidated a trifecta of practices and that you may find useful in navigating a complicated world.  When you use your knife I hope that you think of them:

-Speak your truth.  The media says that we are in the post-truth era, an age of alternative facts, and other dressed-up horseshit designed to keep you from critically analyzing what’s going on around you.   The reality is that the truth always matters, and always will.  Make sure you know your own truths- the things you know to be right and good about yourself and how you see yourself in the world.  Clothe yourself in them.  Should you ever feel lost you’ll know exactly where they are- they will help you find your bearings.

-You can always make more money, but you can’t make more time.  Time is the currency of our terminal human experience.  While making a living is necessary, be aware of how much of your time you sell to a job that only cares about profit margins and what they can squeeze out of you.  If you ever have any doubts about what you should be doing with the time you have been given, refer to the above bullet point.  You’ll know what to do and you’ll be able to hold yourself in esteem while doing it.

Be kind.  It’s sounds cliche, like something written on a shoddy mass-market pressboard wall decoration in the Housewares Section of Target, but do your best to be kind.  It’s the connective fiber of our collective human experience during our brief time on this lovely little world.  If you can, you will find that the world opens up to you a bit easier, and is perhaps a bit richer and more vibrant.  There may be situations you need to tell someone to eat a big bag of shit.  Only do so out of kindness.

Wishing you many happy years with the Masilda.

The Masilda started with a drawing, a drop point style:

I had a bigger piece of steel than I thought, so the actual knife is a bit longer than the drawing:

Jimping- to prevent slipping when choking up on the blade:

Rough grinds:

Wet-sanding out the machine marks:

The hardening process:

After quench:

After tempering, a satin finish:

A pair of vintage lady jeans from my partner, deeply-loved and well-worn:

img_9238masildablog2

Fiberglass resin will be layered between pieces of denim, like a lasagna.  The pathc will go in as well:

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Now smash the whole thing together:

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The raw material:

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Cut and drilled in, with the blade profile traced in so that i know where everything is:

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Texas Mesquite:

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It smells really good:

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Computer board blank rescued from a dumpster.  It’s just a thin piece of fiberglass board:

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Denim and computer board at 60 grit:

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At 800:

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All ready for glue up:

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Glued and clamped

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Shaping up:

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From here, all the sanding is done by hand:

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The higher the grit you go, the more pronounced the grain and fiber:

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The Masilda:

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masilda2

masilda3

masilda4

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 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.

Knifemaking: The Ace, revisited

“When we are children we seldom think of the future. This innocence leaves us free to enjoy ourselves as few adults can. The day we fret about the future is the day we leave our childhood behind.”

Patrick Rothfuss- The Name of the Wind

(you can read about the original crafting of this knife here)

As I approach early middle-age I find myself surrounded by the children of my close friends.  They are marvelous little beings, unfettered by the troubles of the world, and always see possibilities and wonder around every corner.  In watching many of them grow up I feel like I’m let in on a beautiful little secret as they walk, talk, and become more cognizant of everything going on around them.  Boldly pursuing their curiosities, there is a pronounced presence in their endeavors and the way they move through their little worlds.

This unfettered presence of being is a subtle reminder that as an adult I am always second-guessing myself.  “I wish I had done that better,” I will think to myself, or “I wish I had been kinder.”  Rumination at the end of a bad day can trouble my sleep, and the thought of facing the day the next morning can be daunting.  I will often judge harshly my perceived tumbling through the world and wonder if I am doing any of this right.  There are moments when I find it hard to get excited about anything.  Many of the adults I confide in are often thinking the same thing.  These are merely symptoms of being grown in an extremely complicated world, and as many therapists have assured me over the years, are completely normal feelings to have.

Much of this melts away when I spend time with the children of people I’m close to.  They don’t think about any of those things.  As someone crashing through adulthood, I find that to be deeply reassuring.  I am also reminded that I am in fact an adult- no, you can’t have cookies for dinner, you can’t use your Ipad in the bathtub, and yes I do have to leave (please don’t be sad, I’ll be back).  I’m not sure how such big feelings can be contained in such tiny people.

About four years ago I made a blunted knife for the oldest child of some good friends of mine.  They have a house on some property in the country about 45 minutes out of the city.  They grow mushrooms and berries and have animals and forests.  I know the place pretty well- I helped them move out there.

There are now four children at their home.  They are farm kids in the summer.  I saw all of them the other week when I was doing a side job delivering some water containers to his dad, who uses them to run his homestead.  While he was sorting out another visitor, I went in to say hello to the kids.  They were all confused, except for the oldest, and asked me who I was and why I was in their house.

I told them who I was and that I was there to help their dad.  I was then barraged with questions and chatter- the oldest shows me their puppy, the second oldest tells me she doesn’t remember me, the third oldest asked me why I was there a second time, the youngest doesn’t talk yet but eyes me suspiciously.  Dad comes in and clears everything up.  I don’t think there are too many visitors during a weekday, and I felt that my presence was a happy little gift.  I’ve found the most sincere thing a kid can do is talk to you.

Before their dad and I unload the truck I brought in the oldest, whom I’ve known since he was three, wants to show me his treasures.  He pulls a box out of his room and starts removing things- some small folding knives, a bit of paracord, and a compass.  He is immensely proud and can’t even contain it.  I’m a bit jealous.  As a large man when I get excited it usually scares people.  So I quietly and secretly took in his excitement with him. Whoever figures out how to concentrate little boy excitement and put it in supplement form will make a mint.

His dad and I went out back to unload the truck and this little boy received instructions to make lunch for his brothers and sisters.  A few minutes he comes out with a peanut butter and jelly sandwich for me.  His dad hands me his blunted knife I made a couple years ago and asked if I could make it into a real knife.   I tell him I sure can.

Because in the end, it’s not just a knife.

This little boy isn’t thinking about the bigger picture but I am.  In seeing his reworked knife, I hope this little boy will learn to see what it is to grow and improve as he figures things out.  I hope that he will learn to look back on where he’s been and feel satisfaction in seeing how far he’s come.  I hope he will see what it means to put beautiful work out into the world and the empowerment contained within speaking his truth.  Most of all I wish him to not fret about the future and to trust in his tireless human spirit.  This is the lesson of the Ace.

This was the knife I made him four years ago.  It is a hardened and tempered butter knife that allowed him to get comfortable with carrying a bladed tool. 

The handle was coming off- we’ll put a new one on.  Off with the old:

The blade is re-profiled so it has a point and will cut:

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Giving him a good polish:

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Satin:

Black Walnut:

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Computer board blank for spacing material.  Though it looks yellow, it will be green when fully polished:

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Drilling the rivet holes:

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The part of the handle that meets the ricasso is shaped and polished before glue-up:

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Glued:

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Profiled:

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Shaped.  From here on out it’s all hand work:

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The Ace, revisited:

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Knifemaking: how I spent my summer vacation, and the Persuader, MkIII

“Warrior,

The bite marks soon will heal.

Warriors do not forget how it feels”

Stepdad- Warrior (Jungles Pt. 2)

 

(This is the second part of a story.  You can read the first part here).

On a late afternoon in mid July of 2018, three weeks after I nearly removed two of my fingers on a table saw, I found myself sitting with my girlfriend in a an empty group physical therapy room in a wing of the orthopedic center that had performed my surgery.  My hand had been repaired: a third of my thumb amputated and my index finger wired together to fuse the shattered bones and blown-out joints into one piece.

I had been ordered to physical therapy by my surgeon for two-part treatment.  The first part was wound care.  This would ensure that everything healed as it was supposed to, with no infection or complications, and to keep scar tissue to a minimum. The second part was the actual physical therapy, to regain as much use as possible in my injured hand, which which was currently completely bandaged with only my pinky and ring finger exposed.

I didn’t protest.  Nobody really talks about the aftermath of surviving something awful.  It will take the fight right out of you.  There is a truckload of emotional baggage that comes after the ‘get well’ flowers have wilted, the care cards have been boxed away, and normal life begins to resume.  Bills pile up and normal work responsibilities resume, but you are still fragile and adjusting and most likely carrying the weight of trauma.  Despair, depression, and existential crises of a behemoth magnitude are very real aftermaths of life-altering health emergencies as well as the emotional, physical, and financial burdens contained therein.  All of this greatly lowers your resistance, and I found myself more than willing to do what I was told.

This included a mountain of paperwork filled with verbiage of responsible parties, guarantors, and out-of-pocket maximums, essentially telling me that I would be paying for all of this for a very long time.  My girlfriend filled most of this out for me because I couldn’t even button my pants at that point much less sign my name.

In this room filled with all sorts of proprietary rehabilitative contraptions, I was introduced to Steve, an orthopedic hand therapist and educated hillbilly from West Virginia.  He was assisted by Justin, a former football player and mammoth of a man who was getting a Masters in Occupational Health and working in the office for the summer.  Normally this therapy room would be filled with patients but as it was late in the afternoon, it was just the four of us.

I found out, firstly, that hand therapists was a career that existed, and secondly, and paradoxically, they were the kindest sadists I had ever met.  As we sat down to remove my surgical dressings Steve told me that we would be spending a lot of time together and it was going to hurt a lot, starting immediately.   Boy he was right.  It took him half an hour to get the surgical dressing off as it had fused to my skin and surgical wounds with dried blood and other fluids and had two weeks to calcify to my skin and raw flesh.

Pain, as I would slowly learn, is an extraordinary teacher.  It reveals things about yourself that you most likely didn’t know were there, provided you lean into it a bit.  So I leaned in.  Steve was unrelenting and asked how I was doing.  I told him it hurt like a motherfucker.  “Great,” he said, “let’s keep going.”

When he finally disrobed my fingers I couldn’t look at them.  They looked like raw hamburger that had been stitched up.  I felt a little nauseous and so did my girlfriend.  Steve, however, said everything looked great and as it was supposed to look.  He bandaged my index finger and what was left of my thumb individually with inch-wide gauze dressing.  I was told to come back the next morning to get fitted for splints to protect my healing fingers and instructions for bandaging.

My girlfriend and I left and got Bojangles.  Bojangles chicken had become part of the healing process after one of my pre-operative visits several weeks before.  While the surgeon was concurrently examining my mangled hand, making a surgery plan, and giving me nerve block shots through massive syringes, my girlfriend was holding my other hand and staring away from the carnage and at a stack of magazines across the room.  There was a Southern Living magazine on a nearby table with biscuits on the cover.  “We need biscuits”, she whispered to me.  This was a welcoming distraction because I immediately stopped thinking about my hand and how much all of this was going to cost and thought about the glorious coming of biscuits and fried chicken.  From that moment on Bojangles became Orthopedic Trauma Chicken: the patron saint of reconstructive hand surgery, may her light ever shine upon us.

(Many months later one of her children broke their wrist and the other dislocated his knee.  They too learned of the virtues that Orthopedic Trauma Chicken offered.)

The next day I went back to the office early in the morning by myself.  Steve was waiting for me with some sterile wraps.  He explained to me that the bandages would serve as an infection barrier, but also to help my fingers to keep their shape as they healed, specifically my thumb.  In this early part of the healing process, he told me it was important to wrap them as he had shown me, as that was the desired shape that they would take.  I wasn’t to wash them or put any balms or ointments or disinfectants on them.  The body takes care of itself, he said, and I was to let my body do it’s thing.  Infection was a dangerous possibility and I was to call them if I showed any signs, but the 2,000 milligrams of antibiotics I took everyday kept that from happening.  I did exactly as I was told.  I left with two bright blue removable finger splints made from a thermo-setting plastic.  I could button my pants again.

I went there two or three times a week after work.  It was always in the late afternoon and usually only a couple people were in the therapy room.  Steve would unwrap my fingers and let them air out.  Justin would bring a small cup of water cut with peroxide that I would soak my fingers in for about half an hour.  Steve would then pick off the eschar with forceps to prevent scar tissue from forming.  Every few days he would remove a couple of stitches.  All of this was extremely painful and it went on for a month and a half but I was so glad for those two guys.  Steve would tell stories about the dumb things he did in the boonies of West Virginia growing up, and Justin would regale us with stories of dancing on the bar of a downtown drinking establishment.  Justin also had excellent playlists that he would have going over the speakers.  I came to really look forward to these appointments.

As I sat there soaking my fingers day in and day out I also noticed some other other patients there.  There were several gentleman with work injuries who were there on their company workman’s compensation.  There was a lady who had damaged a tendon in her hand with a kitchen knife, and a couple ladies and gentlemen with wrist injuries.  Steve and the gang tended to all of them.  There was one gentleman who stood out- a large muscular guy whose injury I couldn’t figure out.  I knew he wouldn’t be there if he hadn’t had something serious happen but I couldn’t discern what that was.  One day as I was sitting with my hand airing out waiting for Steve, I heard somebody tell me how good my fingers looked.  It was the large gentleman who came in everyday.  This surprised me because for one; I felt that despite what everyone at that office was telling me, my fingers did not look great and that I was a disaster, and for two; I wasn’t used to talking to anybody but the therapists outside of small pleasantries.

The large man then showed me his left hand and I saw that he only had four fingers.  His thumb was nothing but a nub and his index finger and the flesh immediately below was completely gone.   I had to look twice because it was so completely normal and comfortable for him that I didn’t notice at first.  Amazingly enough, that wasn’t even why he was there- he was an electrician by trade and had torn a major tendon in his bicep that had to be reattached.  His hand, he told me, had happened after an accident when he was nineteen years old.  The surgeon had saved his index finger, but he said he had it removed a month later because he was pissed off that it wouldn’t work right.   Young and dumb, he told me, and he wished he had kept the finger and learned to use it as it was.  He told me to figure out how to work through the pain and get as much use out of it as possible.

……..

While all this was happening I was going to work, and sorting out the massive stack of bills I had accumulated.  Even with insurance, this whole ordeal was phenomenally expensive.  I learned more about the financial workings of the healthcare industry than I ever cared to.  Shortly after the surgery, which was covered by my insurance, I got a $4,000 bill from the anesthesiologist, saying it was an out of network provider and not covered by my insurance.  After spending hours on the phone with the insurance company, the surgery center, and the anesthesiologist, I found out that it should have been lumped in with my surgery but wasn’t.  The reason for this was because the tax ID for the anesthesiologist’s claim was in-network, but the provider they sent wasn’t.  All three of them told me I was stuck with this bill and there wasn’t anything they could do for me.  Through some stroke of fate, I found that my neighbor worked in insurance and knew the billing manager of my surgery center and gave me her number.  I spoke with her once and I don’t know what she did but she waved her black magic healthcare wand and made it go away.  That was just one incident of many, but it was always a whiplash.  I renamed my mailbox the Mailbox of Doom because I never knew what fresh hell was going to be waiting for me.

As my hand healed, I got back into the shop a little bit.  Steve had told me that I would be able to do all the things I had done before, but I would definitely have to find different ways to do them.  Finding those different ways added up to teaching myself to make knives all over again.  I found myself thinking of a professor I had in music school.  The man was a brilliant concert pianist.   I didn’t find out till much later that he had suffered a stroke and had to teach himself to play piano all over again- I had no idea of this when I was taking class with him.  The man had since passed and I found myself wishing to be able to ask him about what the rehabilitative process looked like for him and how it felt.

I also called my yoga teacher.  I missed being able to do yoga and asked Steve what I could and couldn’t do.  He told me I could put weight on my forearms, but not my hand.  I told this to my yoga teacher and she choreographed a modified Ashtanga series for me that I could do on my forearms.  She told me to get some yoga blocks to help facilitate this.  When I saw how much foam yoga blocks cost, I decided I would just use a piece of treated 4″x6″ lumber cutoff that I had in my truck.  I did Viking Recovery Yoga a couple times a week and it was brutally difficult.  I leaned into the pain.

……….

Slowly I eased into more physical therapy work and getting facility back into my hand.  Justin had gone back to college and I often met with another therapist, Kay, a lady from Puerto Rico.  She was fantastically kind and gentle, and always wore fiercely hip shoes.  Her husband was retired military and they went on wild adventures on the weekends.  She showed me pictures of a trip where they had taken visually impaired kids on a whitewater rafting trip- all the kids in the picture are tearing ass down river rapids and had on the giant sunglasses that you see the elderly wearing.  At first I wondered how she functioned in such a deeply masculine work environment but the reality was that she was probably the wildest of everyone.

With Steve, I always took a ‘make it suck more’ approach to physical therapy.  Make me do more, give me more things to work on at home, kick my ass a little harder, I’ve got to do better.  With him it was like being at the gym with a buddy.  While I was working through my brutal hand exercises, he would be timing me and telling me about his last bow hunting adventure.  One time he had me dig twenty marbles out of five pounds of silly putty with my two gimpy fingers while he went on a soliloquy about a regional restaurant chain in West Virginia with the best damn breakfast biscuits he had ever had.

With Kay everything was a little bit gentler.  I still pushed but the drive was more subdued.  Conversation was turned inward and bravado was dialed way back.  She asked about how things were going in the shop and I would do my best to articulate all the digital nuances I was navigating and modifying.  My type A disposition would be disarmed before I even knew it was happening and she would talk me through issues I was having.  It was a lot.  After I had spent forty-five minutes struggling with an exercise, she would always tell me I was doing really well.  I would then go sit in my car and cry before I drove home.

……..

 In December I had another smaller surgery to remove the hardware that had been in place while the bone in my index finger fused.  Compared to everything else it wasn’t that big of a deal.  In February of 2019 I had my last post-op follow-up with my surgeon.  Before he discharged me from his care and the care of the physical therapists, he told me I had healed very quickly and my results were not typical of people who sustained my severity of injury.  I told him that I didn’t have a gold plated insurance plan and zero workman’s compensation.  If I gave up I would just sink.  There was no other choice.

I also told him that there were a lot of people who had invested a tremendous amount of time and energy into a very expensive process to help me, and it would be a huge disservice to everyone, including myself, if I didn’t honor that by doing the best that I possibly could.

This was the first knife I completely finished after I was discharged.

This steel came from a friend.  The man they bought their house from made lawnmower blades and they found these in the garage when they moved in.  This is a 1/4″ oil hardening steel:

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Rough grinding:

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Hand sanding before hardening:

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Hardened

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Tempering:

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Satin finish:

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Spalted Pecan from my cousin in Texas:

The black lines weaving their way through the grain is actually a fungus.  This fungus that injures the tree actually makes it more beautiful:

The Persuader:

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Move on, but don’t forget how it feels.

 

Knifemaking: having a quiet day and the Woodsman, Mark Deux

‘In silence there is eloquence. Stop weaving and see how the pattern improves.’

-Rumi

From mid-January to mid-June of this year everything had been a blur.  I was running from job to job, gig to gig, knife to knife, trying to stay on top of everything.  Every time that I felt like I had room to breathe, something else would come up.  Car repairs, state taxes, doctors’ visits, new tools.  It was always something and I was hustling left and right, making sure everything was moving forward and getting taken care of.

Then I had an accident that pretty much stopped everything.

I injured two of my fingers pretty seriously on a table saw.  I was cutting some very thin material when the saw bound up and kicked, and I couldn’t get away fast enough.  The shop is at my partner James’ house and he happened to be home when this happened.  I quickly grabbed a dirty towel and, doing my best not to panic, politely yelled that I needed to go to the ER, right that second.  

On the ride to the ER, which was about twenty minutes away, I took stock of the situation.  James, who teaches shop and technology education, asked me to double check that my fingers were still attached and not on the floor of the shop.  Indeed they were still attached.  I would be told later that I was very lucky to keep my fingers- none of the major tendons or arteries were damaged beyond repair.  

I do my best to practice calm in my life.  Strong reactions happen from time to time, and the best way to deal with them is to feel them, let them pass, and address what caused the strong reaction in the first place.  This is an incredibly challenging thing to do and I don’t always do it well but I’ve gotten better at it over the years.  On the ride to the ER I found impossible to calm down.  I noticed that my thoughts were manic and erratic and I had trouble breathing normally.  I felt a pretty deep sense of guilt and shame, as if I had this coming because I wasn’t slowing down.  A doctor would later tell me that what I had experienced was an acute stress reaction and was normal for what I had experienced, largely in part from the sheer volume of adrenaline and other chemicals that my body had released.  

The ER was a miserable experience.  The ER doctor told me they would need to operate but they would need to transport me to another facility because there was no one covered by my insurance at that particular hospital.  Nobody even looked at my fingers and I sat on a hospital bed and bled on myself for two hours before someone gave me any pain medicine.  The paramedics finally arrived and bandaged my hand- the first time anyone had done anything. They pumped me full of IV fentanyl before loading me onto an ambulance to go to another hospital.  Those guys knew how to get shit done, and in my very stoned state I kept telling them how glad I was that they were there.

We got to the next hospital, and my girlfriend met me there.  In my state of shock I had forgotten my phone at the shop and James had called her.  I was really glad she was there because it would be another four hours before the surgeon showed up.  As it turned out he was not covered by my insurance either.  Somebody had screwed up. 

The worst part about the ER is that you are forced to make life-altering decisions when you are in a state of shock, and/or heavily medicated and not in your best of faculties.  The surgeon gave me the option of going ahead with surgery but understood if I didn’t want to- he was very kind and professional, and pretty pissed that this was the way the system was working.  I opted not to have surgery that night because it would have medically bankrupted me.  I would never have been able to pay that kind of money back.  I would have to find another surgeon on my own.   He cleaned and temporarily stitched me up enough so that I could safely leave, which involved two incredibly painful nerve block shots and a pretty shoddy cast courtesy of the ER nurse- I think it was her first.  By the time we left, my pharmacy had closed and the hospital wouldn’t send me home with any medication.  I had to make it the night without pain pills or antibiotics (I would end up taking 2000mg of Keflex a day for 20 days- I was so filthy when I went in they were afraid I was going to give myself sepsis).  We went home and tried to get some rest, because the next day would be busy.

I think this was what it looked like when the system fails you.  

……

The next morning we got on the phone.  We called my insurance company and they found a place that would take a look at me right away.  Ironically enough their office was located at the first hospital I had gone to the day before.  I met with an orthopedic surgeon and his nurse practitioner.

I found out that orthopedic surgeons do a lot of hip and knee replacements on the elderly, so when a young person comes in with an exciting injury everyone wants to see.  I had no less than six people come and look at me, all very excited. 

The doctor was really excited to work on me- he was an artist and I was his canvas.  He drew me a picture of the procedure he would do and explained the whole thing.  They were going to fuse the middle joint of my index finger which the table saw had blown out, and remove a bit of my thumb.  I got another two painful shots of nerve block while he examined everything and moved some things back into place.  There aren’t a whole lot of words to convey how painful those shots are- I nearly crushed my girlfriend’s hand with my good hand.  My surgery would be two days from then, and they told me to rest.  So that’s what I did.

I have always had trouble finding quiet places and allowing myself to rest.  Now I had no choice.  I called my work and told them what happened and that I wasn’t sure when I would be back in.  I had to cancel some contractor work and push back a lot of client work.  That was what hurt the most.  My girlfriend and I watched a lot of Netflix, something we rarely ever do together.  I don’t watch a whole lot of TV but over the next week I would watch more TV than I had in the past five years.  And honestly it was really nice to check out.  I slept a lot and took pain medication and was generally kind of dopey.  I told my girlfriend that she was beautiful and I loved her, frequently.  I couldn’t bathe myself, or put my contact lenses in, or dress myself.  I just had to surrender to everything and let myself be helped. 

…..

Two days later we went to have surgery done.  I have never had any surgical procedure done before and was really nervous.  They took me in the back and had me put on a hospital gown and fixed up an IV in me.  After a large bump of a sedative they gave me a giant nerve block shot in my shoulder, which made my entire arm go numb.  I was dopey but still semi-conscious when they wheeled me into the OR.  They had music piped in- Bryan Adams was playing.  From what I understand of these things, the anesthesiologist has you count backwards from one hundred till you knock out.  Apparently they didn’t do this with me- I knocked out on my own singing ‘Heaven’ from Canada’s most famous musical export.  I think this was an auspicious sign.

…..

After surgery everything was kind of fuzzy.  We went home and my girlfriend put me in her bed and told me not to get up while she went to pick up my prescriptions.  My entire left arm was completely numb from the nerve block and I remember being really hungry.  Apparently I got up and ate an entire box of her kids’ Pop-Tarts while she was gone and then swore to her that I didn’t.  There were Pop-Tart wrappers all over the place- I don’t remember any of this.  I slept a whole lot and my dead arm, which I was supposed to keep elevated, kept falling and hitting me in the head.  I had a whole pile of pills that I had to take and my girlfriend dutifully kept me on a tight schedule.  The best I could do was tell her that I loved her and tell her how beautiful she was.

The next four days passed like that.  She took off from her high stress-job and looked after me. She helped me bathe, made sure I was taking my medicine, and kept me fed.  I would get really weepy from time to time.  It was all a lot; the trauma from the accident, the bone-deep pain from the surgery, and the bills that would be coming (because even with insurance these procedures are very expensive), and the people I felt I had let down.  Then there was this really wonderful woman taking care of me telling me that it was ok and how well I was doing.  The pain medication peeled away all of the armor I usually wear to function in the world and so from time to time all of this would hit me and I would just sit there and cry.

A few days later we went to clean up my apartment.  I had gotten off the major pain killers to see how my hand was doing so I could get back to my day job.  In situations where there is a caregiver and a care receiver things can turn toxic and codependent— I’ve seen it happen.  The pain pills can be addictive and I didn’t want to be a patient or lean on anyone if I didn’t have to. 

I had a couple of my friends come over to help.  I couldn’t really do a whole lot.  My girlfriend spent two hours cleaning my shower- a knifemaker’s shower can get really dirty.  One of my friends washed all my dishes for me.  James had let me keep my car at his place till I could drive again, and I finally went and picked it up.  And I started going back to work.

……

My two fingers have been in special splints as they heal, so I’ve been doing everything with eight fingers instead of ten.  All the simple things I do that I never think about, like brushing my teeth or packing a backpack or making a sandwich, suddenly require a lot more thought and take twice as long.  It’s really draining and frustrating and a full day of that makes me really tired.    

One thing that continually catches me off guard is the amount of help that is available.  Whenever there is something I can’t do there is always someone right there to help.  Shortly after the surgery I was working a large concert and I had trouble getting a pack of snack crackers open.  I had to grab a union stagehand, an older gentleman with a long white ponytail, and ask him if he could open my crackers for me.  “Well sure brother,” he says.  “Everybody needs a little help now and then.”  Cue waterworks from me.

Getting back into the shop has been scary, and a slow process.  I was in the middle of this knife when I injured myself and I had to keep emailing the client to push back when I would have it finished.  I did all of the woodworking and leatherwork with eight fingers.  It’s been an exercise in leaning into fear and getting back on the horse. 

I tend to have a lot of quiet days of late.  Quiet days allow everything to settle and help one’s focus to reset and help one to cultivate a sense of gratitude.  They also allow for deep processing and healing.  This is also lesson of the Woodsman.  Any good person of the Woods knows how to find quiet and the goodness that comes from within.  The second part of this build has been an exercise in just that.

O1 tool steel, out of the forge:

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Hand sanding:

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Computer board for the spacing material:

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Mesquite from Texas for the handle:

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All profiled:

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Rough shaped on the grinder- from here out it’s all hand work:

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This is at 220 grit:

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Letting a bit of oil set in to help the grain to speak:

The Woodsman, Mark II:

Knifemaking: finding a way and the Desert Fox

“So many people live within unhappy circumstances and yet will not take the initiative to change their situation because they are conditioned to a life of security, conformity, and conservatism, all of which may appear to give one peace of mind, but in reality nothing is more dangerous to the adventurous spirit within a man than a secure future.”

John KrakauerInto the Wild

 

The Desert Fox, also known as the Fennec Fox is the smallest member of the species Canid.  They can be found in the Sahara Desert of North Africa.  Living in such averse conditions has allowed for some particular adaptations in order for them to find their way in their environment, most notably their prominent ears (I mean, look at those things):


The ears help them to dissipate heat, as desert temperatures can get up to 117 degrees Fahrenheit during the day. They also have a specially evolved set of kidneys allowing them to go without water nearly indefinitely and their required moisture can be obtained from their food.  Unlike other foxes or canines, they have fur on the bottoms of their feet.  This keeps them from burning their feet when traveling over hot sand.  Their cream-colored coat helps to reflect the heat of the sun.

They are omnivorous, eating insects, lizards, and birds, but are also known to eat roots, leaves and other vegetation.  The Desert Foxes are social creatures, live in groups, and mate for life.

I find this to be an incredibly encouraging little animal, finding home and company in a place where a large portion of its environment is actively trying to kill it.  On days where I’m not sure how to find my own way, I often think of the Desert Fox.  I find that I don’t have to worry about blistering heat, numerous birds of prey, even more numerous venomous snakes, or scarce food sources, and then I proceed to count my blessings and pray that I don’t become complacent in my station from lack of natural predators.

Because finding your way when there isn’t anything pushing you can be just as hard as navigating a desert full of bad things.

I was in Pittsburgh recently, taking an Uber to dinner.  I’ve never particularly cared for riding Uber; it always feels like there’s an expectation for conversation and an uncomfortable and resentful silence if that expectation is not met.  On one Uber ride in Manhattan there was a driver from the Caribbean who wouldn’t stop talking about his kid and showed my friend and I a video of him playing baseball.  All this while driving in rush hour traffic.  This most recent Uber ride was not that.

The man picked us up and the conversation was easy.  After a little while of talking about what we were doing in the ‘Burgh, I asked him what he did for a living.  He said that he had been a private investigator in Los Angeles for twenty years, from the early ’80’s to the late ’90’s.  He said he had seen it all: cheating spouses, runaway kids, you name it. He thought it was all hilarious.  He wanted to write a book.

His friends all thought his stories were great and they had been encouraging.  The only problem, he said, was when he sat down to write he couldn’t get anything on the page.  He just froze.

I know what this is.  This is the crippling self-doubt that almost every writer and creative person I know deals with.  Myself included.  I told him so.  Hell, I know a filmmaker who has a Crippling Self-Doubt Room in his house where he goes before he works on his projects.  If you don’t find a way forward, you get stuck, and your ideas aren’t heard.  Nothing happens and life goes on.  You have to live with the sting of unrealized potential.  That sting becomes more painful as the years go on and there is no more time to realize what could be.

The only thing to do, I told him, was to find a way to be with that debilitating feeling of self-doubt.  Find a way to get something, anything, on the page.  Once there is something on the page finding your way becomes much easier, and it can take you to surprising places.  There is meaning in those places, satisfaction, and everything becomes a bit deeper and beautiful.

This is the lesson of the Desert Fox, a creature that has an unforgiving place to call home yet finds a way to thrive in it, and makes an existence in the uncomfortable.  If there is something eating at you and calling to you, then you can always find a way to make it happen.

 

We start with flat stock O1 tool steel:

Roughing in the blade choil:

Profiled:

Rivet Holes:

Hand sanding the bevels before heat treat:

Hardened:

Tempered:

Hand-finished satin:

Texas Mesquite.  One of my most favorite materials to work with:

Shaped:

Sanded to 220 before giving the grain a burst:

The Desert Fox:

If you can find a way to exist in the uncomfortable, than you can almost always find a way forward.

fennec fox

Knifemaking: the courage to be and the Ace

“If you love something, you know what the best in the world actually looks like.”

James Altucher

 

This blade was a commission for a six-year old boy who lives on a farm.  His parents are close friends of mine.  They have several acres of property in Montpelier, which is about 40 minutes outside the city.

I go out there as often as I can, usually just to get away from the city.  They have goats, chickens, ducks, pigs, and other animals.  I keep turning down offers to hunt.  I’m not much for guns or shooting things but I have made knives for them to skin and clean with, and I will always eat whatever they brought back, provided it’s already dead.

I’ve known this little boy since he was about three.  He loves to play and is curious about almost everything.  He asks questions that I don’t really have the answers to but I always answer him as best I am able.   He is open and fearless and kind.  He loves his family and everyone close to him is a dear friend.  He sees the best in everyone and wants to help as much as he can.  I have to remember to watch my mouth when I spend time with him.

As an adult I see this as profound and courageous and often inspiring.  This what I would call the Courage to Be.  But as a little boy he is only doing what he knows how to do.  He just loves and in those moments I can feel that whatever he has going on is pretty much the best thing ever.  As a former little boy, I know this feeling well.

I was out there recently for dinner and he showed me where he had lost a tooth.  I asked him if the tooth fairy had visited him and he lost it and screamed “THERE IS NO TOOTH FAIRY” and ran out of the room.  Apparently, his mother explained, he had found out the tooth fairy does not exist.  She said he threw her two dollars at her and demanded his tooth back.

His little world was shaken and he wasn’t afraid to let the big people know how he felt.  Sometimes I wish I could get away with demanding my tooth back…

I was out there the other day and his father needed a hand installing a new washer and dryer.  I had this little boy help me while his father did chores.  He kept asking me when we were going to play and make things.  I couldn’t lie to him.  I told him I had to help his dad and I might not have time for play.  He wasn’t very fond of my games- break the water line with the channel locks, hold the door while I cart out the old dryer, hand me a screwdriver.  I thought we were having fun.  I like hanging out with this little being, even when there is much to do.

And then this little boy had a meltdown.  Tears and everything.  “All you do is work,” he says.  “Maybe you work and save some time for play and then maybe you won’t be so tired,” he says.

I asked him if he would like a hug, and he said yes.  I didn’t tell him I had come out there to have his mother help me with my resume.  I didn’t tell him that his parents work hard and sacrifice so he can play and learn and Be.  What I did do was put him on my shoulders and tell him to hold on tight.  He said he wasn’t scared.

This is the lesson of the Ace.  To find the Courage to Be, even when the grown-up world has dimmed your shine and made it painful to love without condition.  To know what the best in the world looks and feels like, even when you have trouble paying your bills, or sorrow makes you weary, or there are many moments when there isn’t enough of anything.  To know that while you are not going to get your tooth back, you don’t have to like it or settle for anything less than you believe you deserve.

I had traded a skinning knife and a small paring knife for some supplies from his parents.  This little boy found them and said he wanted one.  His parents found a two-foot machete in his play fort.  The little boy said it was for “keeping bad guys away.”  I have seen no bad guys in the vicinity so it must be working.  They asked me if I could make a small knife with a blunted edge for him to carry and learn with.  I then asked the little boy what kind of knife he would like.  I received a drawing and a strict set of parameters, the last of which required that it be a sword.  Right little man, I’ll get right on that…

This is what I came up with.  A blade for a smaller hand.  He’s an inch across at his widest point.  This is the smallest blade I’ve ever made.

full flat grind…

 …hardened and tempered…  

testing for handle fit…  

  The grip is a piece of Mahogany floorboard

The Ace: O1 tool steel with a satin finish, Mahogany handle and brass hardware.


I made a small leather sheath for him to carry it with.  The blade is blunted and I ground the tip down per his parents request.  He’ll grow into it and I’ll build him another one when he’s ready.

Take note of the little ones.  Try to find your Courage to Be.

Snow days and the importance of letting yourself be

(Originally published 2/23/2015)

I’ve always enjoyed a good snow day.  I like the idea of everything slowing down. I like how quiet it gets and how the familiar gets cloaked in white, allowing one to see it in a totally different perspective.  Most of all I like the stillness of it all.  Living in the fan you can always tell who decided they weren’t going to drive or go to work by the layers of snow on all the cars.  I find this to be very calming.

IMG_1618One of my favorite things to do is to go drive places in the snow.  Just to see everything in it’s moment of winter culmination.  With all this snow we’ve had I try to make it to the woods.  It’s quite stunning:IMG_1619

I think what I love most about all of this is that everything just is.  The trees don’t complain, the river doesn’t get anxious, the trail isn’t bothered by the snow.  They’re all just in their moment.

This is the point where I become quiet.  And I don’t really notice it.  So often there is the tendency to feel like there isn’t enough time or enough isn’t being done and I lose my moments being consumed by those things.  Doing.  Always doing but not necessarily accomplishing.  I want for more of the quiet of being and It seems so elusive at times.  Then there are times when it is right there, familiar and loved, like a worn book you’ve read dozens of times.

Then there is the state of becoming aware of these moments of being and trying to hold onto it rather than just let it be.  In trying to hold on to these these things I find this is where I suffer- probably where many people suffer.  I aspire to be more like the trees- bending in the breeze, bathing in the rain, and being patient under a blanket of snow.  Continually growing and present with all of the elements in their world all while being deeply rooted.

There were deer out today.  I’m sure they are out everyday but they are especially conspicuous in the snow.  I really wanted a picture, because seeing deer running through the snow doesn’t happen in my world as often as I’d like.  They are fast.   I walked some more.  After awhile there was a deep moment of stillness and this happened:

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Ethel and Geraldine. And then they were gone. Apparently Thursdays is bingo day at Pony Pasture…

Moments and being and snow days.  Doing is important but if it’s a full time job then you miss all the nuanced bits of your world and life becomes extremely uncomfortable.  It’s a beautiful thing to slow down and surrender to those moments.