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Japanese War Swords Part I

BLADE Staff
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Japanese War Swords Part I

By Leon Kapp

Japanese swords are iconic as ever

It was over seven long decades ago on Sept. 2, 1945, that the Japanese signed the agreement formalizing their surrender, for all intents and purposes officially marking the end of the Second World War. The ceremony aboard the deck of the USS Missouri in Tokyo Bay took all of 23 minutes to close the book on a conflict that extinguished more lives and destroyed more goods and property than any before or since.

While the world has changed much since then, one of the most iconic symbols that existed long before and throughout World War II—and continues to resonate today—is the Japanese sword.

TRADITIONAL vs. WWII SWORDS

Traditional Japanese swords have been made for almost 1500 years, with the fully modern Japanese sword appearing during the Kamakura period from 1185 to 1334. Japanese swords were the symbol and badge of the Samurai class right up to the beginning of the Meiji period (1868-1926) when Japan began to modernize. At the beginning of the Meiji period, the demand for swords fell drastically, and, by the early 1900s, very few swordsmiths were still working—and even fewer were making swords as a full time profession. There was not much of a demand for swords at this time, and what demand existed was satisfied by the existing stock of swords made right before the beginning of the Meiji Restoration.

In addition, a new type of sword had been designed for the Japanese army. These were called Murata To or Murata swords. They were forged from foundry steel and had a simple hamon (aka temper line) made by quenching in oil rather than water. Generally, these were light and thin compared to traditional swords and were mounted in European-style mountings.

A Japanese first lieutenant in a 1930-31 uniform holds an 1886-style kyu-gunto sword mounting. Note the large “D” ring over the hilt. (Richard Fuller image)

However, by the 1930s Japanese military forces were rapidly expanding, and the leaders of the Japanese military organizations decided that all officers in the army and navy should carry a traditional Japanese sword to constantly remind them of their cultural heritage. This led to the development of a new style of sword mounting (koshirae), and also efforts to train new swordsmiths and ensure the new swords were made to traditional specifications and quality.

 

It was decided that all officers should carry a sword, and that meant that about 20 percent of army personnel and about half of navy personnel were eligible to carry swords. From the information provided by Yasukuni Shrine, this meant that around 2 million Japanese military personnel were eligible to wear swords. Some estimates from historical data suggest that about 2 million swords were produced in Japan from the 11th to the 19th century. This meant that the military wanted to produce almost as many swords in the 20th century as had been made in the previous 800 to 900 years.

This photograph was taken in China in 1941. The Japanese soldiers in the front row all have swords in an array of different types and styles. (Richard Fuller image)

This was a very large number of swords to make, and there were not enough smiths or material available to make so many swords. It has been estimated that the town of Seki probably produced about 70 percent of the wartime swords, and the rest of the production took place all over Japan. With this scale of production, it was impossible that all swords could be made to strict historical standards. There simply were not enough smiths or enough of the traditional Japanese steel called tama hagane to do so.

JAPANESE SWORD STEELS

As a result, several types of swords were made during the period. The best ones were made from tama hagane and were fully traditional in terms of hamon and shape. Since there was a shortage of tama hagane and time, many swords were also made from puddled steel, a type of steel made in Europe during the late 1800s and early 1900s. Japan imported this type of steel for railroad rails. When the railroad tracks were replaced, the puddled steel was salvaged for use in swords. Apparently, there was a large supply of puddled steel, and it became the favorite substitute for tama hagane. The quality of the puddled steel was very good. In fact, the Eiffel Tower was also constructed from this type of steel.

The resulting swords have a visible jihada (surface pattern) and hamon, and were very hard to distinguish from tama hagane swords. Japanese military authorities were concerned about this, and, by 1940, a regulation was passed requiring that any Japanese sword not made from tama hagane must have a stamp on the tang indicating as much. Hence, from 1940 all swords had to be signed, and if they were not made from tama hagane there would be a stamp on the tang above the signature solely to indicate as much.

This is the tang and signature on a sword made in 1943 by Hiromitsu of Chikuzen in Kyushu. Note the star stamp above the signature and near the top of the tang. The stamp indicates the sword was made from a type of steel other than tama hagane. Various military contractors or forges used several different stamps. (Aram Compeau image)

The swords made from puddled steel appear to be identical to tama hagane swords, but a high-quality polish can reveal differences in the surface and jihada. In addition, the hamon on puddled steel swords have characteristic differences from hamon on tama hagane swords, and it requires experience to recognize the differences.

This style of Japanese army sword and mounting was introduced about 1944. The mounting diverges from that of its predecessor in that the hilt wrapping is different, often there are two pins or a screw and a pin to secure the sword in the hilt, and the scabbard (not shown) is lacquered a matte shade of khaki or brown. (Aram Compeau image)

Other swords were made from foundry steel and have no jihada and often no hamon, either. Many are found in mounts or koshirae that are different from the standard World War II koshirae, and serial numbers may be stamped on the blade, or they appear to be modeled after European-style blades and mounts. The Japanese cavalry used many of these swords early in the 20th century, as did the police and civilian workers. The swords also were worn in parades or for formal occasions. In general, these other types of blades are easy to distinguish from traditional swords.

A sword by Masatsugu features a visible surface pattern or jihada on the blade. The thin white lines form the jihada, and the lines form short and somewhat discontinuous tracks on the surface. The blade probably is made from 19th-century puddled steel. (Aram Compeau image)

 

MOST IMPORTANT MAKERS OF MODERN JAPANESE SWORDS

The most important makers of modern Japanese swords were found in Seki, in the Nippon To Denshujo, and at Yasukuni Shrine. Yasukuni  Shrine and the Nippon To Denshujo were in Tokyo, and there were other organizations located all around Japan. Yasukuni Shrine’s forging group was established in 1933 with the support of military officials, and all the smiths took names beginning with Yasu, such as Yasunori, Yasuoki, Yasutoku, Yasumitsu, etc. All of these swords are collectible and sought after today.

The Yasukuni smiths were among the most important makers of Japanese swords in the World War II era. Among them was Takeshita Yasukuni, maker of this sword in Hokaido in 1943. It is large, heavy and long (27 inches long) for the period and has a complex hamon. This smith’s swords appear in civilian or non-military mountings as well as military ones. The large size and style of some of his swords resemble work from the 15th century. (Aram Compeau image)

The Yasukuni smiths were expected to make everything by hand in a completely traditional manner and with no power tools. Ideally, one smith working with two assistants or hammer men (sakite) was expected to produce between 10 and 15 swords a month. Yasukuni swords were unique in one other interesting respect: the smiths were asked to model their work after specific blades made by Mitsutada of Bizen Province from around the mid-1200s. Thus, most of their work followed a consistent pattern, and Yasukuni swords are usually recognizable today by their shape, hamon and general style.

Next time, in the conclusion: Such great Japanese swordsmiths as Kurihara Akihide, Yoshihara Kuniie, Kasama Shigetsugu and others, the role of Seki city, the Manchurian Railway Co., war-era koshirae, Japanese army and navy swords, Japanese swords as war souvenirs and more.

GLOSSARY of JAPANESE SWORD TERMS

Hamon—temper line
Jihada—blade surface pattern
Koshirae—sword mounting
Puddled steel—steel from railroad rails used to make Japanese sword blades
Sakite—swordsmith’s assistants or hammer men
Tama hagane—traditional steel for Japanese sword blades

 

 

 

How to Collect Knives: 7 Knife Collecting Tips

BLADE Staff
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How to Collect Knives: 7 Knife Collecting Tips

Purveyors help knife buyers and collectors with what they need to know

Working with a reputable purveyor/dealer enhances the knife acquisition experience. The buyer/collector develops a sense of trust, with time and money well spent as the dealer provides advice and access to certain knives that otherwise may be hard to find.

Talking with a dealer offers an educational opportunity, but often enough the experience falls short of realizing its full potential.  What questions should buyers and/or collectors be asking? Going to the source of the answer is a good place to start.

Bob Loveless knives are amongst some of the most sought-after knives in the collecting world. Photographed above is a Loveless Big Bear in sheep horn and Dan Wilkerson engraving (PointSeven knife image)

1. Know the Knife Collecting Trends

Loveless knife specialist John Denton says that staying informed is important.

“This has got to be through the old way of human contact,” Denton observed, “sort of like the lunchroom in school. You hang out, listen, see what is moving, what dealers are buying and, of course, now with the ‘inter-web,’ we have so much more information within seconds, while in the ’70s or ’80s we had to wait for BLADE® Magazine or the gun magazines to run stories on Loveless. Shows are still important to attend, but nowhere like they were years ago. Face to face is still part of the knife world.”

2. Maker Charisma 

Gauging which knives and makers are hot is an integral byproduct of the dealer’s intuition and experience. How does the dealer determine what makes a knife or knifemaker hot? A lot depends on whether the maker has the kind of personality that appeals to the knife enthusiast.

At BladeGallery, Daniel O’Malley specializes in one-of-a-kind custom knives. The answer includes multiple factors. “There are a lot of things that go into making a knifemaker’s knives ‘hot,’” he reasoned. “Part of it is the personality of the maker. When a collector meets a maker for the first time, the collector often has a picture in his head of what the maker will be like. If the maker falls short [of the collector’s expectations], it can be quite disillusioning.”

3. Customer Service

“[The maker] being willing to repair knives when there is a problem is also very important,” O’Malley continued. “It can easily make the difference in a collector continuing to purchase a maker’s work. It can even be the difference in whether a person continues to collect the maker’s knives over time. After all, if a collector has spent a large sum of money on their collection, it can be very nerve wracking to find that it’s hard to get a damaged knife repaired. Similarly, it can be comforting if a problem can be relatively painlessly solved.”

Daniel O’Malley of BladeGallery.com said the maker’s willingness to repair a knife when there is a problem is very important.

4. Do Your Homework

Les Robertson of Robertson’s Custom Cutlery offers custom fixed blade and folding knives, including tacticals and presentation pieces, as well as some exclusives. His take on the delicate topic of a maker’s reliability and the quality of the maker’s work is sage advice for knife enthusiasts in any price range or level of experience.

“I give my client the very best information I have at the time,” Robertson asserted. “This includes issues with a maker or the quality of their work. Often, a maker’s skill level, quality, customer service, and/or delivery issues are overlooked because the knife can be sold immediately for a profit. Given the prices of many of the custom knives today, I highly recommend that collectors do their homework before purchasing a knife. I realize this takes away from the thrill of instant gratification and removes some of the fun out of the hobby. Long term, though, you will feel great about every knife you have bought, and your wallet will thank you.”

Les Robertson said many buyers/collectors make the mistake of overlooking a maker’s skill level, quality, customer service, and/or delivery issues because the knife can be sold immediately for a profit. The presentation Bastion Dagger by Tim Steingass features an armor-piercing tip. (SharpByCoop knife image)

 

5. Set An Allowance

Everyone, it seems, has spending limits. The role of the dealer often involves assisting clients in determining how much to spend. Recognition of the amount of disposable income available keeps a buyer/collector in the game.

6. Collect with a Purpose

Denton advises customers to acquire some knowledge on prices and to assess their real purpose for buying custom knives in the first place. “First of all, you want collectors to be educated,” he commented, “and not to be buying just to make money. That is the most risky way to approach collecting. But then if they buy what they like and in three years can’t get 10 cents on the dollar, it will cut their knife buying down and drive them out of the market.”

Dealer Dave Ellis of Exquisiteknives.com notes that the investment perspective differs greatly from that of the collector who wants to enjoy, build and retain knives for years to come. “When I chat with newbies,” he remarked, “a lot of them get into knives from an investment standpoint. They have read in the Wall Street Journal that investing in knives is a good idea, or heard about a knife that was purchased for $800 and then sold for $8,000. I tell them to buy what they like first and to worry about resale later because if it doesn’t pan out, then they won’t have to hold onto something they don’t like.”

Taking a measured approach is key to successful, price-sensitive acquisitions. “I tell the collector to pace themselves,” Denton said. “Get into a knife that will be easy to turn if you get tired of it down the road. I’ve had several people ask me to build them a $300,000 collection, and I tell them I don’t do that because they will get mad if they don’t make 14 percent growth per year—and they don’t know why they’re buying the knife. The true collector has studied the knives and the market, and he will realize what knives are worth and what he can resell them for.”

Those who are new to the custom knife market can tap a great resource in a top dealer. Advice on the market, prevailing prices and hot makers is only part of the relationship. High-end folders by BLADE Magazine Cutlery Hall-Of-Fame© member Ron Lake, Warren Osborne and Jim Martin, along with Loveless fixed blades are among Ellis’s offerings, and when he talks with a new buyer/collector he asks a few basic questions.

“There are more heavy hitters getting in the game with lots of money,” he said, “but that doesn’t mean they are buying the right things. What have their interests been up to now? Did they grow up with knives? Do they carry and use a knife? What is their reason for buying now? Use it? Collect it? Give it to a nephew for college graduation? I don’t want to offer a $7,000 Loveless hunter when a $150 skinner by any smith will do.”

Above: Purveyor Dave Ellis—seated at left with Mick Strider at a past California Custom Knife Show—says to always buy what you like first and worry about resale later. The fixed-blade art knife is by E.C. Loerchner. (Dave Ellis images)

7. Attend Knife Shows that Fit

Though knife shows may be one of many ways to gain information and see what is out there, the individual contact with dealers, makers and other knife enthusiasts is invaluable. Attending shows that mean the most to the individual buyer’s needs and wants helps in the education process and in finding the people and knives that enhance the experience.

Robertson attends the BLADE Show due directly to its diversity of custom knives for sale. He says that the Arkansas Custom Knife Show is also one of the premier forged blade shows and features apprentice, journeyman and master smiths in the American Bladesmith Society.

“The New York Custom Knife Show offers a variety of knives from very well-known custom knifemakers,” Robertson added. “This show in recent years has had more of a tactical knife flavor. The USN Show offers the widest variety of tactical folders you will see at any show in the world.” These are just a few of Robertson’s picks. Other shows are out there, and many of them are quite beneficial to knife enthusiasts looking for certain styles of knives and/or makers.

DEVELOP a DIALOGUE

The questions are endless. The enjoyment of knife collecting can be boundless. Develop a dialogue with a dealer. Ask the questions herein and others that come to mind, and feel the positive energy of a well-executed knife purchase.

Who Made the First Damascus?

BLADE Staff
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Who Made the First Damascus?

The origins of damascus steel date to as early as 1500 BC.

The allure of damascus steel lies not only in its beauty and utility, but also in the mystique of its origins. Though its development began in ancient times, the word damascus has grown to encompass more than one method of steelmaking, and the earliest method is believed to date back to 1500 BC.

“Damascus steel today can mean at least three things,” explained blacksmith and steel authority Rick Furrer. “First, there’s pattern-welded steel where a bloom of steely irons is welded into a solid mass which then has a pattern. This is the oldest of damascus-steel-making technologies and one which most blacksmiths reproduce with layers of modern steel welded together.

“Second is crucible steel, where the material is fully melted in a container and then the resulting ingot is forged into a bar, which may or may not have a surface pattern. Third is overlaid or inlaid wire, gold, silver, copper or such into a base metal surface such as steel or silver to make a surface pattern. Some call this damascening or damascene.”

Those who have studied the origins of damascus tend to agree that pattern welding did happen first and that it occurred in the Far East, the Indian subcontinent, the Middle East, Indonesia and Europe. Crucible steel production is also referred to as wootz, and its beginning, for some, is easier to pinpoint.

“Some call crucible steel, or wootz, the original damascus, but pattern welding predates it by more than 1,000 years. Pattern welding was in Europe by 1100 BC in Greece and easily by 600 BC in Central Europe. It was very widely spread by 400 BC,” observed Furrer, who in 2011 participated in the filming of a Public Broadcasting System NOVA segment on the famed Viking swords from circa 800-1000 AD with the Ulfberht inscription. The extremely low slag content of the Viking blade steel may indicate a new development in steel processing in Europe, or that the Vikings were forging blades from imported crucible steel.

“The earliest examples of blades made from wootz steel date from around the first century BC,” related ABS master smith Kevin Cashen, “and the oldest examples of the material seem to come from India. While the Indians seem to have been the first to produce crucible steel, they were soon followed by other cultures in the Middle East such as the large production centers in what would now be Turkmenistan and Uzbekistan. Pattern welding is a trickier process to pinpoint, date or credit to a given culture as it is very old, and just about any people working iron would have produced welded blades on some level.”

Technological Advancements Of Demascus

As technology evolved, production methods improved and fueled the availability of high-quality blade steel. Performance and purpose have contributed to the growth of the industry and the changes in the scale of production through the centuries.

“All of these steel processes were driven by warfare and weapons technology,” noted ABS master smith Steve Schwarzer. “As soon as someone discovered a new method, everybody who wanted to survive jumped on that new method. The moment the local smith developed a method to heat steel to a totally liquid state and control the carbon, the need for wootz and pattern-welded blades fell to the wayside except for the very few who viewed it as art. When the Bessemer converter came into use [in the 1850s] and steel was produced in tonnage at any carbon level desired, there was no need to use the labor-intensive process of making one small piece of material at a time.”

The basic tools used by early makers of pattern-welded damascus were quite similar to those used by the modern bladesmith—hammers, anvils and forges. Dan Farr hammers hot steel in his shop. (Dan Farr image)

Nonetheless, the craftsmanship and performance of forged damascus is timeless. Modern damascus makers take advantage of improved technology and know-how. The ancient producers worked with basic tools and equipment during a process of both production and discovery. The early makers of pattern-welded damascus combined bloomery steel with varying properties, says Cashen, but the basic tools were quite similar to those used by the modern bladesmith—hammers, anvils and forges.

“One difference is possibly the absence of the fluxes we use today,” Kevin added. “The simple bloomery products of that time period, when worked in a charcoal fire, would weld much more easily and not require the oxygen barriers that we have become so accustomed to today.”

The early crucible process would have involved sealing some amounts of premade iron along with certain organic/carbon-bearing materials and fluxes into a clay crucible that would have been placed in a charcoal-fired furnace, which would usually have been fired by a bellows or natural air drafts.

“The clearest difference in either method now compared to then is the fuel we have at our convenience today,” Cashen commented. “Gas-fired forges and furnaces make the tasks much more convenient than the arduous, dirty labors at ancient charcoal fires.”

Staying True To The Steel’s Roots

Maybe it is true that the more things change the more they stay the same, particularly as it relates to damascus steel. Surviving examples of either pattern-welded or crucible damascus are impressive in their quality. Modern bladesmiths produce damascus and mosaic damascus/canned steel that simply defies description, the beauty of the patterns speaking for themselves.

One of the differences between the way damascus is made today as opposed to centuries ago is the use of flux—applied here to a twisted billet by Tim Britton. (Britton image)

Damascus also originally occupied a transitional period in human history. As the Bronze Age waned in Europe, basic iron blades began to appear and pattern welding followed. In the East, iron blades of piled construction were made and pattern welding may have taken place concurrently with it, both being phased out as the crucible process came along. Most experts agree that Europeans were introduced to crucible damascus/wootz during the Crusades.

“With the wootz made by high-temperature smelting in a crucible and forming a cake, bulat or ingot, this ingot was then formed in a very slow, methodical process to produce a beautiful pattern of iron-carbide ferrite and cementite banding,” Schwarzer commented. “This was called watered or damascus steel. It is thought Europeans encountered this material for the first time during the Crusades near Damascus, Syria. Then, this cast material was traded all over the world.”

ABS master smith Al Pendray is well known for his work in wootz steel. Along with John D. Verhoeven, he is listed by the U.S. Patent Office as one of the inventors of “a method of making a steel article having an external surface appearance and an internal microstructure resembling that present on an antique ‘Damascus’ steel sword or blade.” Pendray contends that the earliest crucible damascus was made in Persia and quickly got the attention of Westerners who came in contact with it. “Wootz is ultra-high carbon and will take a real clean edge,” he remarked. “With all the nonmetallic stuff and impurities floating to the top in the process, it’s also a super clean steel.”

But Why Call It Damascus?

As intriguing as the steel itself, the name damascus has a mysterious origin. While the obvious link is to the ancient capital of Syria, the answer to the source of the steel’s moniker is open to speculation.

“One such story maintains that only wootz can be called damascus steel because it was wootz that the Crusaders first encountered in the Middle East, with the town of Damascus being the trading hub for its distribution, thus lending it the name,” Cashen offered. “This theory ignores the fact that there were also damask cloths [with intricate patterns formed by weaving], and that the treatments on many materials involving carving, inlay or otherwise were worked with an intricate flowing or water-like pattern called damascene. It is also worthwhile to note that an old Arab term for water is damas, a coincidence that’s hard to ignore when you consider the number of cultures that refer to patterned steel as ‘watered’ or having ‘watering.’”

Speculating about the origin of the name is intriguing, but Cashen says it is what it is. “In any case, the number of centuries that any steel with a pattern in it has been called ‘damascus’ sort of renders all of these speculative picky semantics irrelevant,” he noted. “Languages evolve, and the word means what it does today. When this is taken into consideration, any steel possessing an induced pattern could be safely referred to as damascus, with pattern welding or crucible steel being the more specific types of patterned steel.”

According to Master Bladesmith Steve Schwarzer, modern steels are far superior to even the best of the ancient materials because of quality control and repeatability.

Finest Blades Ever

As with many highly prized skills, individual bladesmithing and the production of high-quality damascus steel in small quantities has been eclipsed by mass production, given the availability of modern equipment and technology. However, the steel still owes its lineage to the blacksmiths of ancient times. Additionally, today’s bladesmiths keep the tradition and the skill alive like no mass production process can.

“Modern steels are far superior to even the best of these ancient materials because of quality control and repeatability,” Schwarzer mused. “What modern steels don’t have are beauty and the visual fingerprint of the steel artist’s hand. The damascus blades being made in modern times are far superior to the ancient blades because the modern smith is using these very sophisticated steels and modern scientific techniques to produce the finest blades ever made.”

DIY Engraving Vise or Block

BLADE Staff
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DIY Engraving Vise or Block

The bowling ball vise makes knife handle work easy and inexpensive

As the old adage goes, “necessity is the mother of invention,” but whoever thought of making an engraving vise out of a bowling ball deserves a medal!

The engraver’s vise, which has a rotating base so the craftsman can position his work at any angle, has been around for many years. Small versions are affordable but one big enough to accept a large knife handle can cost in the $600-to-$700 range.

Enter the bowling ball vise.

American Bladesmith Society Master Smith Don Hethcoat has made several bowling ball vises, including one for fellow ABS master smith Joe Keeslar. Both makers find the vise particularly useful for inlaying gold and silver wire into knife handles. “I learned about the vise in 1988,” Hethcoat recalls. “I wish I could take credit for creating it, but I first saw it being used by Firearm Engravers Guild member John Barraclough.”

“The first and only bowling ball vise that I ever had was a gift from Don Hethcoat many years ago,” Keeslar says. “In my Kentucky shop I use an engraving ball for my silver wire inlay work, but for my shop and demonstrations in France I use a bowling ball vise. I could not afford to buy a second engraver’s ball for my shop abroad.”

Used bowling balls are cheap, and beyond that the biggest expense to making a bowling ball vise is adding a machinist’s vise on top of the modified sphere. The cost for these items is a fraction of what an engraver’s vise costs, and the rest of the materials to complete the vise are very affordable. Indeed, they can be found around your shop, home or at your local scrap yard.

IMPROVISING WELCOME!

While the basics of making Hethcoat’s bowling ball vise are outlined in the below photo, there’s no reason you can’t add your own personal touches or substitutions. For instance, Don uses a piece of round pipe for the base of his vise, but Joe has a different way of skinning the cat. “My bowling ball sits in a lawn mower tire with the rim removed,” Keeslar notes. “It’s best to have a tire with rim diameter of about 6 inches. If no used tire is available, a new one can be found at a Harbor Freight store.”

There are other differences between the two makers’ vises. Hethcoat uses a bench-mount machinist’s vise mounted to the top of his modified bowling ball, while Keeslar prefers a low-profile drill-press vise commonly used for drilling and milling. Both vises work fine and your choice may be determined by factors such as your height in relation to your workbench or the configuration of the vise jaws that suit you best.

The jaws of the vise will need to be padded to keep from marring the knife handle. Here again, choose your preferred padding material. Thick leather will work as well as high-density foam—or take a look around your shop and use your imagination.

ROLL on a BUDGET

As a long-time instructor on how to make knives, Keeslar says beginning students may not have the money for expensive equipment, so he uses his bowling ball vise as an example of how they can get started without a huge investment.

“I personally use an engraver’s ball for my silver wire inlay, but the bowling ball vise is very inexpensive to make and affordable to use,” Joe observes. “When doing demos here in the U.S. [and abroad], I use the bowling ball vise to demonstrate to my students an easy way to get started in doing wire inlay. I also show them how to make the stabbing chisels and the like. So much of what is needed to produce knives is expensive and this is one activity that one can do for a small investment.”

It’s all about saving money. The extra cash you save by making a bowling ball vise can be poured into better handle materials—everything from wood to wire. This translates into a more upscale knife for your own satisfaction or, if you sell your wares, a higher price you can get from a customer. You’re a winner either way!

6 Easy Steps to Make the Bowling Ball Vise

According to ABS master smith Don Hethcoat, “Bowling balls make the perfect vise for knifemakers doing inlays and similar close work where you need both stability and flexibility. You can buy an old bowling ball at a flea market or thrift store for two or three dollars.”

In his own words, here are Don’s six steps:

1) “Saw off about one-third of the bowling ball, getting rid of the old finger holes. I used a metal band saw but you may have other means”;

2) “Drill five holes in the flat top of the ball, one at each corner of a square with one in the middle using a half-inch drill bit, then chisel out a cavity in the center of the ball”;

3) “Fill the opened cavity almost to the top with lead shot to add weight, then seal the shot to the top of the hole with automotive Bondo® filler”;

4) “Make a round cover for the flat top of the ball using metal, wood or Formica®. Mount your vise on top of this. Mine is a machinist’s vise using its mounting system”;

5) “Make a base and you’re almost done. I used a round piece of 8-inch pipe cut to 2.5 inches in depth. Fill the pipe with Bondo, cover it with Saran™ Wrap and push the bottom part of the ball into it to make an impression. Clean up the excess Bondo [or, you can use the lawn mower tired described by Joe Keeslar in the story]”;

6) “Cut a round piece of suede to fit inside the round cavity so the ball can rotate freely. That’s basically it! Feel free to modify the vise to fit your own scenario.”

Knifemaking Great Mel Pardue Passes

BLADE Staff
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Knifemaking Great Mel Pardue Passes

Legendary knifemaker and teacher Mel Pardue passed away recently, leaving an incredible legacy in his wake.

One of the greats passed away over the weekend. Renowned custom knifemaker Mel Pardue of Repton, Ala., leaves an incredible legacy in his wake. In addition to his custom work and collaborations with top manufacturers, Pardue was a respected and honored member of the knifemaking community.

Pardue was a BLADE Magazine Cutlery Hall of Fame® member and a voting member of the Knifemakers’ Guild for almost four decades, 14 of those years as a member of the board of directors, the final 10 as vice president. Furthermore, Pardue received the Ron Little Award in 1992 and is a past winner of the Guild’s Red Watson Friendship Award. In 2016, Mel was presented with the BLADE Show’s Aldo and Edda Lorenzi Award for his outstanding work in teaching and mentoring his fellow makers in the art of building knives.

An inventive and consummate professional, Pardue made his first knife in 1952 and regularly created new designs since 1956. While he produced custom knives throughout his career, he is perhaps most widely known for his work in 24 years collaborating with Benchmade, which produced a number of his designs. Among the most popular and recognizable from this partnership was the Griptilian, an EDC folder that became a prolific part of the Oregon company’s catalog. The manual folding knife with the AXIS® lock eventually became available in nearly every conceivable size and color.

Aside from the creative aspects of Pardue’s career, he was also a dedicated teacher of the art and craft of knifemaking. He was the first person without membership in the American Bladesmith Society to teach at the William F. Moran School of Bladesmithing, where he conducted classes on how to make folders. He taught the same subject at the Batson Bladesmithing Symposium and held seminars and classes in his shop for over 40 years. The drive to pass down his wealth of knowledge was also evident in his family legacy, as his son Joe Pardue and grandson Robert Carter are also well-known knifemakers.

How to Do Plug Welds on Knives

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How to Do Plug Welds on Knives

Plug Welds the David Lisch Way

The ABS Master Smith shows how he puts a plug weld in a damascus blade

On this and the following pages, I will show you how to do a plug weld. Firstly, this is not a new technique. That being said, I would like to think that the way I am using it here is new—or at least it is new to my knives. I’m not showing how I made the damascus pattern as it would take way too many photos. Perhaps I will show that in another story.

The Moon Fighter is one of two knives I have made in this style. The first one was the Sun Fighter. The Sun Fighter was the first time I made a knife using the plug weld technique. I took an order for a knife like the Sun Fighter. Since the resulting knife was slightly different, therefore I named it the Moon Fighter.

HOW DAVE DOES IT

In Photo 1, I am cutting an oval hole into a forged integral blade. I forged the blade from a billet of my Star Night Damascus (Photo 2). It is important that the hole be an oval shape so it will be round once it is forged (Photo 3).

3: It is important that the hole be an oval shape so it will be round once forged.

Blade thickness is just over 3/8 inch. This will give me room to forge the blade once I make the plug weld. Photo 4 shows the end of the moon billet. I will shape the square into the oval to the make the plug for the “moon.”

In Photo 5 you can see that the plug is ready for insertion into the hole. It is close to the right size but just a bit big. I put a slight taper on the edge of the plug so it can “find” the hole. The plug is an eighth inch thicker than the blade. This will allow the plug to expand and weld into the blade.

Above Photos 6 and 7: The hammer is a blur as the author pounds the plug into the hole in the hot steel.

With any process there is a learning curve. I learned that to get a really tight fit with the plug, it works best to put a dull red heat on the blade. Place the tapered plug into place and hammer it into the dull red blade (Photos 6 and 7). In Photo 8 the plug is in place. It is 1/16 inch proud on both sides of the blade. Back into the fire to a dull red and add flux.

In Photo 9 I have made the first weld. The moon is still visible. In Photo 10 the moon is still a bit cooler than the blade and is getting a bit bigger. Now is the time for some heat. Photo 11 shows work at the power hammer for some drawing down of thickness and adding length to the blade. It also makes the oval moon round and very hard to see.

In Photo 12 I am forging the blade close to its final shape. In Photo 13 I am drawing out the tip, adding more length to the blade. The moon is very close to being round. After a few final taps under the power hammer (Photo 14), I will finish tuning up the profile by hand.

NO SET FORMULA

I do not have a set formula for this process. It is by gut feeling. I can see how much the steel moves when I forge it. The first time I tried it I put a round hole into the blade and wound up with an oval, so it made sense to start with an oval hole if I wanted to wind up with a round one.

With the Sun Fighter the blade was 480-layer damascus and the “sun” was a very tight W’s-pattern damascus. Once I made the initial weld, the blade was still over 3/8-inch thick at that juncture. I ground in sunrays on both sides then forged up the rays and the sun to its round shape. On the Moon Fighter I wanted the backdrop to resemble shooting stars. This took some trial and error and a lot more time than I thought it would to get a pattern I liked.

The result of the plug weld made to resemble the moon is plainly evident in the center of the damascus blade of the Moon Fighter by ABS master smith David Lisch (inset). (SharpByCoop knife photo)

NO LIMIT

There is no limit to the cool new things that can be done with damascus. I have heard folks say it has all been done before. Well, I don’t believe it. I think new and exciting things are happening in little knife shops all over the world, and the only way to keep things moving forward is to try new stuff and share the new things with everyone we can.

Please feel free to try this process. There are so many different things that can be done with it. When you come up with something new, share it so we continue to advance the art of damascus and knifemaking. Or, buy a damascus knife from your favorite maker and watch for that sparkle in his eye as he thinks to himself, “Cool, now I get to make another knife.”

Marine Vet’s Knife Memorializes the Ultimate Sacrifice of His Iraq Comrades

BLADE Staff
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Marine Vet’s Knife Memorializes the Ultimate Sacrifice of His Iraq Comrades

1 Knife for the Lima Company 11

BY MIKE HASKEW BLADE® FIELD EDITOR

*This article originally appeared in BLADE Magazine Winter 2013

The bond of brotherhood, sacrifice, and selflessness forged by fighting men in combat is, perhaps, the strongest emotion human beings can experience. So it is with Travis Williams.

Having just turned 18, Travis enlisted in the United States Marine Corps In December 2001. He reported for duty the following August and spent the next four years in the service. While he trained, his original reserve unit had already deployed to Iraq, and he was among a few who were reassigned to Lima Company, 3rd Battalion, 25th Marines, another reserve unit, headquartered in Columbus, Ohio.

Travis Williams (second from right, back row) stands proud with his squad mere weeks before the deadly IED strike. (photo courtesy of Travis Williams)

During its deployment to Iraq, Lima Company endured days of patrols in harm’s way, intense firefights, and the ever-present danger of IEDs (Improvised Explosive Devices). With a strength of about 180 Marines, Lima Company lost 24 killed in action, and one in eight of its Marines received the Purple Heart for wounds received or death as a result of enemy action. By late 2005, Lima Company was the hardest hit unit of its size in the Marine Corps. Lima’s battalion lost 48 men killed in Iraq.

 

AUG. 3, 2005

Considering the tedium and tension that encompassed his time in Iraq, a single day stands out in Travis’ memory. On Aug. 3, 2005, during a patrol near the town of Barwanah, 11 Marines from his squad were killed in a massive IED explosion.

“We were going to start at 0600,” Williams recalled. “We loaded our amtracs, big transport vehicles, and about five minutes before we stepped off, a call came down from higher. For some reason the platoon commander and I got pulled out of our vehicle with 1st Squad and put in a vehicle ahead of theirs with Iraqi forces in it. We headed for town and weren’t going to take any roads in. It was about a month before we were to leave the country, and we had seen a lot of firefights and IEDs.”

After the patrol received word that the road was, in fact, clear, the catastrophic explosion erupted. “We hopped on the road, and right as we made the turn for town I was sitting down in the vehicle,” Travis continued. “Somebody has to stand up to provide security, and I saw the explosion in the glasses of the guy standing up in our vehicle.”

Williams still does not know why he and the platoon commander were ordered out of the vehicle that was hit. He was not injured. Fifteen men occupied the stricken amtrac, and he had known those Marines that were killed for more than a year. Among them was his best friend, Lance Corporal Aaron Reed of Chillicothe, Ohio.

Travis and Lance Corporal Timothy M. Bell Jr., 1983-2005, enjoy some downtime. Bell, 22, was killed by the IED. His awards include the Purple Heart, Navy and Marine Corps Achievement Medal with Combat “V” for valor, and the Combat Action Ribbon. (photo courtesy of Travis Williams)

When Lance Corporal Travis Williams returned home to Missoula, Montana, in August 2006, he brought with him the memories and the scars of his wartime experience. He worked as a private investigator for about five years, and then an opportunity that he could not pass up presented itself. Always fascinated and intrigued by knives, he met custom knifemaker James Behring, Jr.

“James moved to Missoula from Michigan in 2011, and he married my friend’s sister,” Travis said. “I would hang out at the shop and watch what he was doing, and finally he told me that he was looking to hire somebody. I jumped in from there, cutting out blades from bar stock, soldering guards and finishing handles and stuff like that—until I was able to make a knife.”

GOLD STAR FAMILIES

This past February, the Wall Street Journal featured Travis in an article observing the 10th anniversary of the war in Iraq. “They wanted to know how I was doing,” he commented, “and there was a video with it and a guy followed me around the shop while we were making knives.”

A fellow Marine veteran saw the article and contacted Travis, telling him that a benefit was being organized for Gold Star Families in Ohio. These are the families of those who have lost a loved one in battle. “He asked me to make a knife for a silent auction, and the proceeds would go to support the work of an artist that was painting life-size portraits of the guys that were killed from the company,” said Williams. “It was on short notice because the event was going to be in three weeks. I cleared it with James and then contacted Roger ‘Mudbone’ Jones of Waverly, Ohio, to make sure he could make the sheath if I got the knife to him in time.”

Mudbone is an accomplished knife and sheathmaker in his own right. A friend of the Behring family who considers James Behring “like my own son,” Mudbone agreed to make the sheath. His relationship with Travis has grown as well, and he simply considers the former Marine a second son. In fact, it is Mudbone who brought this compelling story to the attention of BLADE®.

“Travis called and said he wanted to tell me about the knife and get some pointers on it and the sheath,” Mudbone remembered. “It knocked me out when he said this was for his friends, and particularly his best friend who had been killed. It turns out Aaron Reed was from my hometown, Chillicothe, Ohio. I had never met the boy, but I knew of his mother, who had been a teacher in a local school.”

Travis set to work under the watchful eye and guidance of Behring. The finished knife includes a 6-inch drop point blade of O-1 tool steel, a thick brass guard, and a stacked-leather-washer handle with a butt of whitetail crown stag. Inserted between the leather washers is a piece of the nametape, typically worked across the top of the uniform pocket, of each of the 11 Marines killed on Aug. 3, 2005. The letter “L” for Lima Company and “3/25” for 3rd Battalion and 25th Marine Regiment are hot stamped into the blade.

Made by Travis under the watchful eye of Jim Behring, the knife has a 6-inch blade of O1 tool steel, brass guard, and a stacked-leather-washer handle with a butt of whitetail crown stag. Between the leather washers is a piece of the nametape, typically worked across the top of the uniform pocket, of each of the 11 Marines killed on Aug. 3, 2005. The letter “L” for Lima Company and “3/25” for 3rd Battalion and 25th Marine Regiment are hot stamped into the blade. (photo courtesy of Mudbone Jones)

When the knife was complete, Mudbone set to work. With only a week to complete the task, he crafted a leather sheath with the iconic image of the rifle turned down into a boot and topped by a helmet. A dog tag hangs from the weapon. The word “LIMA” is also prominent.

“On the back of the sheath there are 11 four-pointed North Stars,” added Mudbone. “Craftsmen of earlier times stamped these on guns and knives so the owner could always find his way home. They finished the knife on a Saturday. I got it on Tuesday and dropped everything else to get the sheath done. Sometime around 3:30 or 4:30 a.m. the next Saturday, I pulled the last stitch and put the last wax on it.”

Above: Working from the drawing, Roger “Mudbone” Jones employed a Marine theme of helmet, weapon, dog tags and boots to make the knife’s leather sheath, including the Lima Company name. On the back of the sheath are 11 four-pointed North Stars,” added Mudbone. “Craftsmen of earlier times stamped these on guns and knives so the owner could always find his way home.” (photos courtesy of Mudbone Jones)

SOLD for $7,000

The knife sold for $7,000, but not during the silent auction. “Doc” Wentworth, a Navy corpsman who had been assigned to Lima Company, was determined to keep the Lima Knife with the portraits so beautifully painted by artist Anita Miller. The memorial event at the Ohio Statehouse in Columbus was moving and inspirational, and Wentworth succeeded through social media in raising small donations that bought the knife and will allow the memorial to remain together in its permanent home in the statehouse. An accompanying book, The Lima Company Memorial:  A Remembrance of Spirit and Choice, has also been produced.

UNBREAKABLE TIE

Learning the art of knifemaking and continuing to work with James Behring has proven therapeutic for Travis, and he is pleased with his opportunity at Behring Made Knives. While continuing to work in the shop, he attends events that help other veterans adjust to life after active duty. At some point in the future, he may begin making more knives and even taking orders. For now, he is content to continue learning.

“I like where I am with James’ company,” Williams said. “I do everything from heat treating to finishing blades and handles, and have recently gotten into making Kydex. On some of our CNC knives I’m doing the blasting, coating and sharpening of the blades. James is sitting there watching me, and someday I would like to get to the point where I am making knives on my own.”

Today, Travis finds contentment with his work and sees the future with optimism. There will, however, always be that unbreakable tie to his fellow Marines. Meanwhile, with a little help from his friends, he has created a lasting tribute to his fallen comrades.

Travis and his best friend, Lance Corporal Aaron H. Reed, take five. Reed was among those killed by the IED. His awards include the Purple Heart and Combat Action Ribbon. He was 21. (photo courtesy of Travis Williams)

For more information contact Roger “Mudbone” Jones, Dept. BL12, 320 Prussia Rd., Waverly, OH 45690 740-739-4562 [email protected], or Travis Williams, c/o James Behring, Dept. BL12, POB 17317, Missoula, MT 59808 406-926-1193 (shop) [email protected], www.behringmade.com.

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