Knifemaking: mistakes, tedium, pizza ovens, and the Cynewulf

“I’m not exactly sure what we’re doing here, so we’re going to figure this out by denial and error”

Frederick Pritchett, Jr.

I spent two years working in the warehouse of an auction company.  They specialize in used restaurant equipment.  All aspects, from tables and chair, mixers, slicers, refrigeration, the whole lot.  I kind of fell into this job and ended up managing the inventory and auctions.  But before that there was a lot of grease, dirt, rust, and burnt pizza…

A couple years ago I was in a tough place and I needed money.  A good friend of mine said I could come work for his auction company.  One of the first things they put me on was cleaning three commercial smokers.  They had spent three months festering in a hot warehouse and smelled of what I believe a sauna full of garbage trucks eating month old Vietnamese food would resemble.

It was here that I met Fred.  As I stood there with three stinking smokers, pondering my life’s decisions, the service tech came by and told me the best way to get those clean was to mix some bleach and ammonia together in a spray bottle and shake it till it got hot (“But don’t hold on to it for too long or it’s liable to explode”).  Then I was to saturate the interior, let it sit in the sun, and then hit it with the pressure washer that got up to two hundred degrees.  All while not breathing in the fumes.

I did all of these things and sure enough they got clean.  I hated myself a little bit.

The main thing I learned working here was that there are many ways to get things done.  Some ways are less insane than others, but then sometimes life calls for the insane.  Sometimes the insanity is all relative.

I also learned that in any sort of business one has to adapt to what makes money.  If that doesn’t happen then you’re dead.

One of the owners is second generation Italian and as it would follow many of the company’s customers were Italian.  They liked to support one of their own.  For awhile there were a lot of Italian restaurants opening up and these gentleman required pizza ovens.  Pizza ovens are heavy, expensive, and take up a lot of space.  Pizza stones for a double deck oven will set you back at least $600 and if not properly seasoned will crack or break.  It was decided that we would rebuild used ovens.

Here is where the adaptation of making a profit and the insane got together for a tumultuous marriage.  At first.  After awhile things settled in.  Fred was at the helm of this operation and we all moved bravely forward.

The first step was obtaining a used pizza oven.  We travelled far and wide.  One time Fred and I did a marathon drive to a closed restaurant in Florida, extracted a 3,000lb set of Baker’s Pride ovens, threw them on a trailer, and drove back.  Fred is really good at moving heavy things and makes it look effortless:  I’m pretty sure his ancestors built Stonehenge using nothing but Druid redneck ingenuity and several barrels of barley wine.

We would then strip it down to nothing.  Exterior paint was taken off and everything was sanded.  Everything.  For a solid month we cleaned out every Home Depot within a 20 mile radius of most of their abrasives.  Figuring out how to get the exterior paint off was tricky at first. Stripping the paint off the first oven we did was a bitch.  First we tried a blowtorch.  A pretty big one.  It didn’t work that well and made everyone smell of burnt pizza.  Then we tried every sort of angle grinder attachment known to the universe.  There was no quick way to do it.  All of the inner structural pieces had to be sanded as well.  Somebody would have to put on a paper suit and climb into the behemoth and sandblast it.

In the process of anything worth doing you encounter tedium at some point.  When tedium mixes with not knowing exactly what you are doing, self-doubt can settle in.  It becomes hard to focus and in this lapse of focus mistakes happen.  This is where many people either give up or figure it out.  We couldn’t give up because then nobody got paid.  Fred kept us all on task, for better or worse.

It is also in this tedium that you can find out a lot about yourself.  How you operate and what lies at the bottom of that self-doubt.  If you can be with that long enough you can start to blossom.  The things that used to hurt you start to help you.  I found myself making these really kick-ass playlists and began to appreciate the nuance of Barry Manilow.  When I got home completely covered in shit I would take a viking shower and cook myself something special.  All of the other side jobs I had became a pleasure.  I would see myself as a warrior, bravely defending the honor of the Oven of Pizza, and all of those who came before her.

I would go in and stare these things down everyday.  Sometimes it was overwhelming, sometimes time flew by.  Days of sanding, painting, polishing, going to the metal shop to have a piece refabricated, or having a special tap set ordered.  It was an adventure.  I’m glad Fred was in charge because I would have told the Italians to figure something else out.

Another area of tedium was polishing.  I spent many hours with a Scotch brite pad and 000 steel wool trying to make these things shine.  This was about the time Mr. Al joined us and as fate would reveal he is actually the Stainless Steel Whisperer….

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After Fred put new burners and controls in they would be ready for delivery.  It was a sprawling process.  At the time I stopped working there, the process was down to a week and a half to two weeks, start to finish.  They ship them all over the country now.

 This is the lesson of the Cynewulf.  Life can be a sprawling, tedious process.  It can be hard to stick with something and not being able to see where it is taking you can make it harder.  Instead of seeing yourself as the warrior you start to see yourself as the oppressed.  Momentum can turn to stagnation and focus can lapse.  You begin to question your life decisions and maybe sometimes you hate yourself a little bit.

I find myself in these places more often than I’d like.  And what I’ve found is that it’s not necessarily a bad thing.

This blade took me on a journey.  I had to start over after I had spent quite a bit of time on it and I got really frustrated.  The name Cynewulf means “Royal Wolf”, which relates to the regal bearing and balance of this blade but also to the ability to not get stuck in one’s mistakes or complacent with one’s successes.  It’s quite large at 8 inches and 13 inches overall.  It was really tricky to heat treat in my little forge.  I hammered it through some 2×4’s just to make sure she was ready for the world.

1095 spring steel

A rough grind
Ready for the forge

Phosphoric acid etch…

 The Cynewulf: 1095 spring steel with an acid etch, Cherry handle, and brass hardware. 

  

  The Cynewulf, with her fallen sister…

I gave this to my chef friend to try out and he ended up buying it on the condition that I customize it to his specifications, which I did.  You can already see the patina starting to reveal itself from the potatoes he sliced…

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Work through the tedium and pay attention your mistakes.  Even the kingliest and queenliest people make them and there are many possibilities in them.  There may be some pizza in it at the end…

Knifemaking: befriending what tries to hurt you, process and mistakes, and Brigid Marsal

“I build the road and the road builds me”

-African Proverb

I think about this saying often.  Sometimes you work and it’s hard to see progress until you look back and see how much road you’ve built.  Maybe you think about giving up until you look back and realize the only way to go is forward.  Parts of the road may be shoddy or weak or bumpy but it came from you and that is a beautiful thing.  It’s a process and sometimes parts of the process are bumpy and shoddy.  I’ve found the bumpy parts are the most sacred because that’s where the deepest lessons are.  It’s important to not skip or ignore the bumpy parts and to be with them as fully as you are able.  This is sometimes difficult or even painful but it is often times the only way to move forward.

I started building a forge to harden my knives.  Her name is Brigid Marsal.  In Celtic folklore, Brigid is the goddess of fire and fertitlity among many other things.  Marsal is a make of pizza ovens.

This is not my first attempt at making a forge.  Brigid 1.0 was a woodstove at the warehouse that I fueled with charcoal and bellowed with a shop vac on reverse.  It was loads of fun but never quite did the job.

Funny story.  This summer I was on a pretty hellacious job with Fred and Mr. Al in a mall in Kensington, Maryland.  The mall was set to be demolished and we were there to extract some safe deposit boxes, some dental equipment, and a gigantic Marsal double stack pizza oven.  One of these stacks alone weighed about two thousand pounds and they were covered in a brick facade.  There really wasn’t a lot of room to work because the kitchen was built around the ovens.  So here are Fred, Mr. Al and I trying to wrestle this monstrosity onto our crank lift which is really only rated for maybe eight hundred pounds.  The lift breaks, the monster of an oven comes crashing down and I had to dive onto the counter to avoid being crushed.

We all collected ourselves and found that there wasn’t any way to move these ovens without help.  It took another trip up there to get the ovens and thankfully I was not invited to go.  The ovens came back, were rebuilt, and sold.  There were a few of the heat stones left over.  Fred gifted two of the unbroken stones to me to build a forge.  Turning something that nearly kills you into something that works for you- I like this idea.

Here are the devil stones:

According to Fred they are liquid poured and can handle temperatures of up to “infinity degrees.”

They are also ridiculously difficult to cut.  They are dense and stubborn and have a tendency to crack if you don’t go slowly and patiently.  The satisfying part is to see how far you’ve come.

What starts as this:

Becomes slowly cut away into this:

And you have to do it one pass at a time, evenly.

The idea with this particular design is to create a vortex of heat to bring the knives evenly up to critical temperature- about 1500 degrees.  To do this I cut the stone into square- or as close to squares as I could get them.

many hours later…

I put a two inch hole into three of them.  There is no quick way with stone.

On one of the pieces I added a half inch hole in the side for the blow torch.

I lined the stones up to give it a go….

Pretty, but not quite vortexing the way I would like…

So the forge doesn’t work the way I had planned.  What I found was that the stones, which hold heat very well, are not so good at reflecting the heat, which is what I need.  There is still another forge to build but I am going to use the Marsal stones somehow- to remind them that I am not so easily crushed…reminders of bumps in the road you build and sacred lessons along the way.