Behind the Blade

Every custom knife starts with your vision. We’ll discuss your ideas and requirements, then create a detailed sketch for your review. Together, we’ll refine the design until it’s exactly what you want. Once finalized, I make a precise metal template to guide the forging process, ensuring your knife matches your expectations.

I work with premium steels such as 1084 high-carbon steel, 5160, 80CrV2, and W-2 tool steel. These materials are chosen for their durability, excellent forging properties, and ability to hold a sharp edge. Using these steels ensures your knife will be reliable, resilient, and tailored for lasting performance.

Forging begins with heating a steel bar to the ideal temperature. The blade’s point, plunge, bevels, and taper are shaped first, followed by the handle or tang. Careful temperature control throughout prevents overheating and preserves the steel’s integrity. The blade is forged to roughly 85% of its final form before moving to the next stage.

Forging introduces stress to the steel, which must be relieved for optimal performance. The blade is heated above its critical temperature and slowly cooled—repeating this cycle three times to fully normalize the steel. Next, the blade is annealed by heating and then cooling it slowly in vermiculite, making the steel soft and easy to work with during the next steps.

At this stage, the blade starts to reveal its final shape. I begin by profiling the outline, then grind the ricasso, bevels, and tang. After rough grinding, the blade is normalized again to relieve any new stresses. The blade is now ready for the critical quenching process.

Quenching is where the blade truly becomes a knife. The steel is heated to a precise temperature and quickly cooled in oil, locking in hardness. At this point, the blade is extremely hard but also brittle, making it unsuitable for use until it’s tempered.

Tempering reduces brittleness and fine-tunes the blade’s hardness. The blade is heated in a temperature-controlled oven for two hours, cooled, and this process is repeated twice. The exact temperature depends on the steel type, ensuring the perfect balance of strength and flexibility.

The knife returns to the grinder for final shaping and finishing. Starting with a coarse 60-grit belt and moving to finer grits, I refine the blade’s surface. Some knives are finished here, while others move on to hand finishing for an even finer touch.

Hand finishing involves meticulous sanding by hand to achieve a consistent, polished look. This step gives each blade its unique character and flawless finish.

With the blade complete, it’s time to fit the handle—using stabilized wood, G10, or Micarta, based on your preference. After shaping and polishing the handle, I craft a custom sheath from leather or Kydex to protect your knife and complete the process.