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: the Lioness, revisited

“The stuff we make don’t go bad”

“The ugly dog barks the longest”

Tray Eppes: potter, musician, fully present citizen of the Universe

(you can find the initial crafting of the Lioness here)

So a number of years ago one of my best friends asked me if I wanted to play a gig with him and his godfather.  It was a Christmas parade in a small town about two hours away.  We were both in music school and played near any gig we could get.  Neither of had cars at the time and a big ass Dodge truck piloted by a gentleman with a large beard pulled up.  This was Tray.  On the way we stopped at a jazz club, had a few cold ones, and heard some badass tunes.  We got to Tray’s farm at around 2am and he showed me his guitar rig (at full blast).  I went to sleep to the sound of coyotes howling.  I got up and Tray’s wife had made us smoked venison with Hollandaise sauce on a lightly toasted English muffin.  We drove to town and played brass band versions of Christmas songs and it was a blast.

We played those parades for the next couple of years.  We spent a New Years out there.  As I recall we drank gin and sat in the outdoor hot tub in front of a fire the size of Rhode Island.  I make sure to keep in touch with Tray and his wife.

A couple months ago I was standing in the middle of a field working security for a country music concert, alone with my thoughts due to the fact that most of the audience was in the beer tent and there wasn’t much securing to do.  In those moments I often find myself thinking about places I’d rather be and in this case I would have rather been, well, almost anywhere else.  I decided I would call Tray and see how he made a living making the things he makes: killer pottery.

He told me about selling pottery to the Amish.  The Amish don’t have any possessions that are purely decorative. If there are pictures on the wall, it is most likely a Bible verse written in a modest calligraphy.  Likewise, nothing is frivolously decorated.  This particular group, Tray was telling me, used white dishes.  Tray also told me that white pottery is a bit more labor intensive than his normal work and the Amish are the only ones who ask for it.  So he can make a large batch of it and have it on hand and not have to fool with it for awhile.  He was explaining to the Amish man he can make it and sell it years later.

“Ahh”, said the Amish man.  “Not like spoilt cow’s milk.”

This was when he told me the stuff we make doesn’t spoil.  You can go back and rework things that you aren’t happy with.  I’ve had a few proverbial ugly dogs barking at me and recently I’ve been reworking those.   And it’s not limited to just pottery, or knives, or music…just because you were one way yesterday doesn’t mean that’s how you have to be today.

Tray also ordered a knife and a sheath.  I made him this:

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For the Lioness I found the blade to be too thick.  I went and ground down the bevel, which in turn improved the balance of the blade.  I wasn’t happy with the finish so I took care of that as well.  All of this came from a gentle place.  Nothing is going to spoil.

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O1 tool steel, Cherrywood handle, and brass hardware

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The nice thing about refinishing a wooden handle (or wooden anything) is that the grain is so much more prominent due to the permeation of the finishing oil.  The grain pops much more grandly than it did the first time around.  I see it as a little gift for going back and trying to make it better.

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I also smoothed and polished up the tang.

Tray and a much younger me

Tray and a much younger me

Check out Tray’s site at here and drop him a line

Knifemaking: honor, integrity, and the Hound

Both sides of my family were landless sharecroppers and mountain people from as far back as I can remember…What did I receive from this lineage?  Things I believe to be very valuable: a good raw intellect and a good tough body…A sense of honor that results in a touchiness common to our people…When the only thing you own is your sense of personal honor, you tend to protect it at all costs.

Eric L. Haney, Inside Delta Force

This blade was initially a commission from another very dear friend of mine.  He asked for a knife that was based in a sort of old-world honor.  A sort of honor that is maybe not seen so much today, at least not on the surface of things.  Something that may get lost in performance reports and email threads.  Something that isn’t tied to how much money you do or do not make, what deity you do or do not pray to, what color your skin may or may not be, and completely independent of whatever gender with which you happen to identify.  A sort of goodness that comes from having a place in this world, of knowing deep within your being that you deserve to be here and that no one can take that away from you.  He asked that it be called the Hound and I got to work.

There are times in my life when I have felt empty and hollow, like something was missing.  I tried filling this with all sorts of things- material things, a busy schedule, pharmaceuticals, and overindulgences of food and drink.  What was actually missing at those times was a personal bearing.  In more difficult times I had traded my honor for things that were fleeting, for a sense of security, and for a feeling of belonging.  When you have something to ground yourself in and can carry yourself in esteem, the aforementioned things will find their way to you, though at times it may feel like you are a thousand miles away from any of them.  No one gives this feeling to you.  Some people have this from an early age, others have to find it, and still others go through hell and many trials by fire to figure out what it is for them.  Some people have been beaten down so far that they aren’t aware that it even exists- but still it can be theirs.

When you act and speak from this place it brings an integrity and truth to the things you do.  A resonance that permeates everything- like an orchestra, where a balance of intonation, volume, harmony, and depth of emotion makes a gorgeous sonic mass.  There may be chaos all around you but within you everything moves in synch, just like the bows of a symphony orchestra.

I “finished” this blade some months ago and was never quite happy with it.  I’ve since made a blade of the same bearing for my friend, the Hound Mark II (here is a picture).  I didn’t find the initial bevel work on this knife to be satisfactory and I didn’t come to this conclusion till after I had hardened the steel.  One has to be careful grinding on hardened steel: if it gets too hot the steel loses it’s temper.  So with a cup of ice water I took the bevel to where I was happy with it.

It’s important to not give away our honor, as it can be the thing that gets us through when there may not be anything else.  As it follows, I added a sturdy grip on the Hound.  I wanted it to melt into the hand and hold fast for times when holding anything may be challenging.  
  
Profiled, ground, and sanded  After hardening…
During tempering…    Roughing in contours…Cherrywood for balance….
Mostly sanded…  The Hound
  
  
  
  

The Hound was made from O1 tool steel with a Cherrywood handle and brass rivets.  Hold to your honor.

If you find you would like to purchase one of my blades or have me craft one for you, email me or check out my Etsy store.   It may end up on this blog…