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

Knifemaking: the Halvard

“Kinsmen to kinsmen should be true.”

~The Saga of Olaf Haraldsson, c.186

The Halvard was built for a retiring military commander and commissioned by his crew.  A battle ready knife, built to use, but equally at home on display with merits of a successful career.  

Made from 1095 hi-carbon steel with a forced patina: a rugged appearance lending itself to rugged tasks.  The handle is made from a pair of BDU trousers, a nod to service, and a reminder that, though he may no longer wear the uniform, the uniform is always with him.

This knife took a long time to build.  About midway through the build we had to shutdown our shop due to a global pandemic, and getting back into the swing of things hasn’t been easy.  Nevertheless as we build these knives, we find that the knives also build us.  Halvard is a Norse name meaning “rock guardian”: solid, unbending, and steadily dedicated to the task at hand.

It was a pleasure building this knife for a group of Vikings.

halvard1

halvard2

halvard3

halvard4

halvard5

 

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:

blog1

Now smash the whole thing together:

blog2

The raw material:

blog3

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

blog4

Texas Mesquite:

img_7566

It smells really good:

blog5

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

img_8132

Denim and computer board at 60 grit:

blog6

At 800:

blog7

All ready for glue up:

blog8

Glued and clamped

blog9

Shaping up:

blog10

From here, all the sanding is done by hand:

blog11

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

blog12

The Masilda:

masilda1

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 things that are ours and the Notre L’affaire

“But then I have always been somewhat of a square peg in a round hole.”

Cressida Cowell- How to Speak Dragonese

 

When I was five years old I had my first lesson in finding out that the world might not be built for me.  I was not in kindergarten yet because I had told my mother that numbers and letters had looked too hard for me.  Perhaps I really wasn’t ready, or perhaps I was just stubborn, but this would leave me a year older than all my classmates through my entire academic career.  So at five years old I was sitting with all the other five year old preschool kids who, for whatever reason, weren’t quite ready for kindergarten either.  It was around Thanksgiving time and we were making hand turkeys out of construction paper.  You are probably familiar with the process, where you trace your hand and your fingers become the tail feathers and your thumb becomes the head and then you cut the entire thing out and add all the plumage.   I was having an incredibly difficult time with it.  I couldn’t get my scissors to work and I had no idea why.

As it turns out I was, and still am, left-handed.  They had no left-handed scissors, and the poor ladies couldn’t explain why I was the only one who cut with my left hand.  The silver lining was that when I looked at the wall of hand turkeys for the next two weeks before we took them home I knew exactly which one was mine- the sort of mangled looking, Mattisse-inspired one with it’s shredded, soft edges and pastel color themes.  It might not have quite fit in, but that turkey belonged to me.

I think a major source of anxiety today comes from a pressure to fit in.  We are pack animals after all, social creatures, and there is a large degree of comfort and safety that comes with fitting in.  For whatever reason some of us just don’t fit.  Maybe our personal values don’t align with the metrics of what society calls success.  Maybe the things in the world that move us have been wrought and tempered in such a way that makes the mainstream feel incredibly dull and boring.  Maybe we were brought up in a fashion that causes us to question the rules and the people who make them.  Or perhaps our idiosyncrasies and the way we see the world simply makes others in the pack feel uncomfortable. 

Because the reality is that life is uncomfortable and existence is messy, and no amount of corporate team building exercises or ‘life is beautiful’ bumper stickers will change that fact.  The square pegs of the world know this, because things have probably always been uncomfortable.  The beauty of being a square peg that doesn’t fit into the circular opening of life is that you find a way of living that is unique and meaningful to you.  Usually that means crashing through more than a few romantic relationships, getting fired from a few jobs, making a whole lot of mistakes, and generally being a mess for awhile.

When you finally pop out on the other side of all that, you may find that what you’ve become is completely and totally your own, free of mimicry and imitation.   All those things that you’ve become- those belong to you and no one else.

(I taught myself to cut right-handed in elementary school to save myself and my teachers a lot of grief.  I cut better right-handed than I do left-handed.  You have to pick your battles.)

This knife was commissioned for a chef at a local restaurant by his girlfriend.  I love making knives for restaurant people- anyone who winds up in food service is totally a square peg.  In talking to the girlfriend, who works in hospitality, she told me that they were both a little crazy, which is part of what makes everything so interesting.  ‘Notre L’affaire’ roughly means ‘our thing’ in the sense of something intimate and personal, like a slightly rough-around-the-edges turkey made of construction paper hanging on a pre-school bulletin board.  You should always recognize and honor the things that are yours.

 

An 8″ chef in the German Style:

Hi-carbon American 1095 steel:

Profiled and drilled:

Into the forge:

Making sure everything is straight:

Grinding the bevels:

img_7555

a5882d54-3626-42c7-848a-b3b1a1c3a553

Hand sanding:

Satin finish:

An acid etch to help with corrosion resistance:

For the bolster we’ll make a material out of bow tie pasta:

After it gets smashed up and set in fiberglass resin…

…you get something like this:

img_7586-e1568582334258.jpg

Texas Mesquite:

Glued:

The Notre L’affaire:

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:

img_7485

Giving him a good polish:

IMG_2835

Satin:

Black Walnut:

img_7486

img_7487

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

img_7488

Drilling the rivet holes:

img_7489

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

img_7490

Glued:

img_7497

Profiled:

img_7505

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

img_7506

The Ace, revisited:

img_7509

 

img_7511

 

Knifemaking: a restoration

“You didn’t get the quest you wanted, you got the one you could do.”
Lev Grossman, The Magician King

Every so often our shop will get calls to put a new handle on an old knife.  We always make every effort to do as many of these as we can.  

The ability to make something broken work in the way that it once did is a virtue.  This is especially true when the something that was broken is special to someone.  In most instances it’s pretty easy to replace what was broken, but the sentiment becomes lost.  Whenever possible I always try to fix what is broken, especially in the shop.

I treat these repair jobs as an exercise in incorporating as many broken or discarded things as possible into the finished product- it gives something totally unique back to the client.   Our jobs as craftsmen are to give a voice to our materials, allowing them to speak for themselves.  Many times we don’t choose what comes to us but nonetheless it is our job to turn what comes our way into something beautiful.  Making something better than it was before-this is the goal of a skilled craftsman.  For those in the know, these are the things that put the color in our world.

A gentlemen contacted us about re-handling an old boning knife he got in the 1970’s.  It was an old Zwilling knife, made from good Solingen steel, with Zwilling’s proprietary ‘Friodur’ subzero tempering process.  The handle had cracked, as natural materials tend to do over the years.

This one was partial tang, meaning the metal in the handle doesn’t run the complete length of the handle:

First, we remove the old handle and the rivets:

For the handle we’re going to use Black Walnut, which was formerly a baseboard salvaged from an abandoned house in North Carolina:

To extend the tang, we’re going to use a fiberglass computer board spacer which I dug out of a dumpster at one of my workplaces.  Though it looks yellow, it will turn green as it’s polished:

img_6337

Drilling the rivet holes.  The black spacing material is a heavy plastic that came from an office mail separator:

This is the top of the handle, closest to the ricasso of the blade, of the belt sander at 40 grit:

Sanded from 60 to 800 grit:

Ready for glue up:

Glued and clamped:

Roughly profiled:

Shaped to the desired shape.  The rest of the work will be done by hand, starting with 80 grit sandpaper and going up to 2000 grit.

Finished, sealed, and oiled:

Always take the opportunity to create something beautiful.

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:

persuader1

Rough grinding:

persuader2

Hand sanding before hardening:

persuader3

persuader4

Hardened

persuader5

Tempering:

persuader6

persuader7

Satin finish:

persuader8

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:

img_6427.jpg

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

 

Knifemaking: therapy for large men, Buddhism with the boring parts left out, and the Rumfoord

“I was a victim of a series of
accidents, as are we all.”

Malachi Constant, from Kurt Vonnegut’s The Sirens of Titan

 

A few years ago I went to see a therapist.  I was stagnating.  I had lost my job and was doing all sorts of ridiculous things to make ends meet.  Over the course of about six months I floundered about.  I worked security for outdoor festivals, fixed toilets in a friend’s apartment buildings, and did tree work with another friend.

I remember being baffled by the whole situation, and feeling like a victim of unfortunate circumstance.  This wasn’t how any of this was supposed to happen.

Knives were not doing well.  As I was sitting there staring at my belly button and not doing anything about my situation, it was suggested by those close to me that I go talk to someone who could help me.  That was the last thing I wanted to do.

After some consideration, and a good amount of trepidation, I called a counseling office recommended by my insurance company and I went in for an appointment.

I remember sitting in a very Spartan office, with lamps suggesting a mood of emotional intimacy, and an institutional nightstand with a box of off-brand tissues sitting on top of it.   My therapist walked in.  He was a large African-American gentleman, crisply dressed, and carrying a folder.

He asked me the formal therapist/patient questions: what I hoped to accomplish in our sessions, and what it was I hoped to gain from our time together.  The truth was that I was a little stuck.  There were things about myself that I missed, a spontaneity and ease of being that I had lost.  I knew where I was and I knew where I wanted to be but I didn’t know how to get there.  Also there was a lot of emotional clutter and traumatic bullshit in the way.  I told him all of this.

‘I think I can help you with that’, he said.  ‘As for the emotional clutter and everything else in the way- I think it’s time to let that shit go’.

So we began.  Nearly every two weeks for about a year, and then maybe once a month for the year after that.  My therapist was technically a licensed clinical social worker who specialized in substance abuse counseling.  I didn’t have any substance abuse issues- I had simply told the administrative lady at the office that I was most comfortable talking to a middle-aged man, and this gentleman had an opening.  He didn’t wear a suit like all the other therapists.  His dealings with addicts, I found, left him with a particular knack for getting to the root of personal problems , and a no-bullshit way of going about it, like a sort of Krav Maga of psychotherapy.  I come from a place where you didn’t talk about how you felt so to voluntarily talk about things that were bothering me was, and is, something that is incredibly uncomfortable.  And honestly I wasn’t looking to talk about what was bothering me- I was looking for someone to tell me what to do.

Of course that isn’t how therapy works.  He didn’t tell me what to do.  He would ask how situations made me feel and then challenge me.  I came in one time really bothered about something and I remember him laughing at me.  ‘Welp, you’re in the shit now’ he said, ‘What do you intend to do about it?’

The bluntness was empowering and it didn’t come with any judgement.  This was simply how one large man was helping another large man.  I would go in and tell him that my shit was all fucked up that week.  And he would nonchalantly ask me if I had a plan for unfucking my shit, and that if I did not, perhaps there were some goddamn unresolved childhood issues being played out and my fucked up shit was just a manifestation of that.  Then we would unpack my goddamn issues so that I could start unfucking my shit.

I would tell him that I struggled with faith that everything would be ok.  He said everybody does.  I told him I had a hard time dealing with disappointment and uncomfortable feelings that came from harboring resentments.  I let him know I was ashamed about not being able to accept failure.  He told me that all these made me a completely normal human being.  Month after month he would talk me off of existential cliffs.  ‘Don’t be a victim’, he would say.  ‘Be a warrior.’

We talked a lot about transformation and how it can be difficult to change.  I would be frustrated about something that was so deeply innate to my being that I didn’t know where to start.  He would gently tell me that a person can only change so much, and some things simply can’t be changed.  And then he would say that some of the things I was trying to change weren’t bad things and I should reframe what it was I was trying to do.  It was a study in Buddhism, but with the boring parts left out, and a whole lot more expletives.  When a sculptor wants to make a statue of an elephant from a block of stone, he simply removes the parts that don’t look like an elephant.  There comes a point when you can’t remove anything else to make the stone look more like an elephant.  This was what we were doing- removing (or at least identifying) the parts that didn’t serve the whole, and accepting everything else with kindness and compassion.  Om Mani Padme Hum…

We laughed a lot.  Lots of sad things came up, and I would get really weepy and reach for the off-brand box of tissues in that intimately lit office.  We talked about music and books and art, and what it was to be a good man and what doing the right thing looked like.   We usually ran over our time limit.

After a while I started bringing in the knives I was making and talking through the stories.  It was like sculpting an elephant, or yourself, but I was taking away the parts that didn’t look like a knife.  I was afraid it might be weird bringing big knives into a shrink’s office week after week but he told me to keep bringing them and to keep telling him their stories.  So I did.  I told him they were guardians that helped me to write the ridiculous experience that life has been for me.  I’ve never done things the conventional way, or even the smart way, and bringing your handmade knives in to help you talk about your story with your large African American psychotherapist probably falls into at least one of those categories.  He was always kind to that part of me.  He told me to keep building little sharp guardians and to keep writing.  At the end of each session I would shake his hand and thank him.  ‘No, thank you,’ he would say.  He said he always looked forward to seeing me on his schedule and to what I would come in and tell him.  I think he dealt with people much more fucked up than I was.

I started seeing him less frequently.  I found, slowly and when not crippled by self doubt, that I was getting to where I wanted to be and was able to find what I needed in myself.  I was doing good things and feeling alright.  He told me that much, and that nobody really knows what they are doing anyway, and he was always there if I needed him.  He also told me to keep my knives sharp.

Every so often, when I’m about to do something dumb, I’ll hear that man’s voice telling me not to be a dumbass and I’ll think twice…

Sometimes one may know where they want to be but don’t always know how they’re going to get there.  The journey to that destination is often the most interesting part of making it in the world.  This blade gets it’s name from one of my favorite books, The Sirens of Titan, where the main character is at the mercy of the whims of chance and destiny (and also aliens), but through the grace of the almighty chonosynclastic infundibulum, ends up precisely at his foretold destiny.  Along the way all of his core beliefs are challenged and his world is completely upended, yet there he is at the end of it all.  This is the lesson of the Rumfoord.

This knife was built for a gentleman who was waiting a very long time for it:

Heating can cause warping.  A sophisticated setup for straightening…

Roughing in a full flat grind:

Removing all the machine marks…

…to achieve something a bit more pleasing.  A smoother finish helps the blade to move through food better.

An acid etch to force a patina.  This helps with corrosion resistance on the high carbon steel.

A PCB board blank from a server chassis.  This will be spacing material for the handle:

Texas Pecan, from my cousin Bill:

Drilling out the rivet holes:

Laying out the handle profile:

The handle near the ricasso, at 40 grit:

The handle near the ricasso, at 1500 grit:

Glued up:

Profiled:

Shaped:

Smoothed:

The Rumfoord: