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: power in the small things and the Petit Poucet

“It has long been an axiom of mine that the little things are infinitely the most important.”

― Arthur Conan Doyle, The Memoirs of Sherlock Holmes

 

When I was twenty-one I took a summer job in a cabinet shop.  I was in between semesters of school and had made some pretty significant life changes, at least for a twenty-one year old.  I had transferred colleges and I decided I wanted a summer job where I would learn something useful.

This particular cabinet shop did custom work.  Everything was built to order.  The owner was a friend of my family’s.  On my first day I was introduced to everyone in the shop.  It was noisy in there, with all the fans and sawdust collection systems, and everyone heard my name as “Bernard” instead of “Ballard”.

I didn’t find this out until later, after everyone had been addressing me as Bernie for at least two weeks.  I was just happy to not be called college boy.

I was hired to sweep floors, which I did for approximately one hour on my first day.  After that hour I was handed a reciprocating saw and told to cut up a stack of pallets.  When they found I still had all of my fingers, they gave me other things to do not involving sweeping the floor.  From then on I did whatever was asked of me, still happier to be called Bernie than college boy.

I built drawers for desks to go in lawyers’ offices.  I would be on a crew of four guys to build an army of receptionist desks for a medical complex.  I built a mile of L-bracket to mount cabinets in an insurance building.  When you work in a shop with over a million dollars worth of tools and machinery there isn’t a whole lot that you can’t build.  The owner liked to make money and I can count the number of times he subcontracted jobs out on one hand.

This was one of the best summers of my life.  I didn’t hang out with anybody.  I didn’t go on any dates.  I got to work at 7:30a and left at 4:45p.  When I got home I would practice my horn for four hours in my parents’ basement and then go to sleep.  Then I would get up and do it all over again.

I found myself spending full days on a panel saw, a massive contraption designed to rip and crosscut full sheets of plywood.  It cut everything perfectly square.  You see these at Lowes and Home Depot but this machine made those look like Tinker Toys.  This particular one was made by a Nordic company that specialized in making badass cutting tools.  It cost about thirty grand and when it broke down they had to pay a company service tech from Pennsylvania $600 an hour to fix it, which included drive time.  Clearly we were all in the wrong business.

I was given a cut list for each job.  Some of these lists would be casework for an entire building, others just one or two pieces.  I cut all the cabinet pieces by hand, within a 1/64th of an inch, which by industry standards is a pretty large margin.  The real tricky bit was cutting cabinet doors and drawer fronts.  These cuts had to be cut short to accommodate for the laminate that would cover the side edges of the door.  This was to allow the doors to fully close once the edge had been covered in laminate and for the drawer fronts to have the proper reveals once installed.  When I would get to the doors and drawers on the cut list I would know to cut them between 1/16th and 1/32nd of an inch shorter than what was written, depending on the type of laminate being used.

I cut hundreds of these things without incident.  Then one day I screwed up.

The boss called me over.  Shit.

I had sent over four doors that I hadn’t cut short, in this instance it was 3/32nds.  They had been laminated, drilled, installed with ungodly priced hinges, cleaned and finished.

“Bernie, you fucked up.  Let me explain to you the depth of your fuckup.”

He proceeded to tell me that not only had I wasted my time, but I had also wasted the time of everyone involved in those doors, plus materials, wear and tear on machinery, saw blades, electricity, and by default, company time that we weren’t ever going to see again.  With everything involved those doors came to about $240.  A piece.  He instructed me to take them and throw them in the dumpster, but to do it one at a time, and to use that time to reflect on the breadth of my folly.

Four long trips to the dumpster.  I was mortified.  Everyone else thought this whole ordeal was hysterical.  I made sure to not overlook the doors and drawers in the future.

The summer came to an end.  I went back to school with a deeper appreciation for both higher education and the people who build the things that make life possible.

There is much power in the small things and sometimes you only find this when you overlook them.  Sometimes they are absolutely necessary.  Sometimes they make the world a bit sweeter.  Small acts of kindness to yourself and others, small acts of gratitude and compassion- these are the stuffs that can give the world its particular hue.

This is where the Petit Poucet comes in.  I have been designing kitchen knives and also watching Jacques Pepin cooking videos.  There was one of these that struck me where he had all these beautiful knives at his disposal, some quite large and impressive, but he prepared a gorgeous meal using only a six inch utility knife.  Petit Poucet roughly translates roughly to Tom Thumb, a very small person who was able to accomplish large things.  It’s important to not overlook the small things.  This is the lesson of the Petit Poucet, a small but mighty kitchen blade.

I started with a bar of 1095 spring steel

After rough grinding and heat treat.  Thankfully he didn’t warp.

Keeping it cool during finish grinding…

 I had some Bloodwood that I found to be striking the Petit Poucet: Acid etched 1095 spring steel, Bloodwood handle, and brass hardware.
  
  
  

Mind the small things- the big things will turn out that much better…and you will save four trips to the dumpster.

P.S.- the man I worked for was possibly the best boss I’ve ever had, and one of the most decent men I’ve ever known.  We still talk from time to time.  He keeps saying he has a place for me in his business and asks me how I am with finance.  If he only knew…