From historic clashes to modern conflict, these fierce custom blades prove there is still a profound amount of art in the tools of war.
Since the dawn of man, the edge of the blade has been used to hash out disputes between everything from clans and tribes all the way to nations. While not the main battle implement in today’s conflict, the martial nature of the knife remains. This particular collection of fierce customs demonstrates there is a heap of art in war.
Caleb Ledford Long Sword
An electric 1084/15N20/mild steel Turkish-twist damascus defines the 31-inch blade of Caleb Ledford’s long sword. Lightening the sizable slicer’s load is a tapered fuller running on its midline. The handle is a pitch-black ebony, and the guard and pommel are cold-blued mild steel.
Jacco Van de Bruinhorst San Francisco Bowie
With matching blade and inserts, Jacco Van de Bruinhorst’s take on the San Francisco bowie is an elegant Barbary Coast brawler. The Canadian maker used ProCut/1084 to create what he calls a “snakeskin pattern.” If you study closely, the inserts harken back to the gold rush days with 24k gold inlay.
Jim Poling Dirk
Commissioned by a descendant of King James IV of Scotland, journeyman smith Jim Poling’s walnut-handled dirk appears freshly plucked from the highlands. The dagger boasts a 13-inch 1084/15N20 twist damascus blade, antiqued mild steel fittings and coin-edged nickel spacers.
Andrew Blomfield Pesh Kabz
Master smith Andrew Blomfield has taken more than one stab at the pesh kabz in his career, and lands the blow with this 11.5-inch bladed example. The eye-catching mosaic blade is contrasted by the very conservative tones of the purple gidgee handle and blackened steel bolster. A traditional flourish, brass blossoms are on the handle’s pins.
Michael Deibert Wakizashi
Alabama-based journeyman smith Michael Deibert brings traditional Japanese styling to life with this striking Wakizashi. The 18-inch blade features 1,100 layers of 1080/15N20 steel, paired with a wrought iron bolster. A classic stingray and an Ito-wrap handle complete the 28-inch overall build.
Nate “Tuna” Grant Pocket Fixed Blade
Nate “Tuna” Grant Pocket Fixed Blade
Journeyman smith Nate “Tuna” Grant delivers a compact powerhouse with the Defender. This 7.375-inch overall fixed blade features a 4-inch flat-ground blade forged from 1084/15N20 steel in a striking diamond drop pattern. The build is finished with rich Mun ebony scales.
Emmett Eitreim Dagger
Emmett Eitreim presents a refined 12-inch overall dagger featuring a 7-inch flat-ground blade. The steel is a striking rose pattern forged from 15N20/1084, complemented by a 954 aluminum bronze guard and pommel. A stabilized spalted maple handle completes this elegant, high-contrast build.
Check Out More Cool Customs:
Cool Custom: Tony Lewis’ Tribute Knife To Steve Dunn
Cool Customs: Rocco Nawrocki’s Knife For Sergeant Bunker
Sometimes You Want A Blade That’s Fun And Exciting Even If It Isn’t An EDC. The Buccaneer Sword From Condor Is All About Having A Good Time.
There’s a pretty good chance you’re not a pirate in the Caribbean or off the Barbary Coast. Even if you’re just a lifelong resident of a landlocked place like Kansas City or Nashville, you’ll absolutely love the new Buccaneer Sword from Condor Tool & Knife.
The massive blade is 15.5 inches in length and is made from 1075 high-carbon steel with a convex. It weighs a shade under 30 ounces so it’s a burly, heavy knife that can be used for bushcraft or for making a big show of slicing large cuts of meats. If you’re a performer, using this sword to prepare steaks for your family at the next barbecue will be remembered for years.
It all stays solid in your hand thanks to the leather-wrapped hardwood handle that is as strong as the blade and stays true while you wield this mighty sword. The included leather sheath will keep the sword safe when stored away.
The Buccaneer Sword is so much fun. If you want a showstopper, and stay on top of maintaining the high-carbon blade, you’ll have yourself a thrilling conversation piece for years to come.
The Cutlass Is A Short Sword Used For Centuries. Today, It Is Mostly A Ceremonial Blade, But One That Continues To Inspire
A sword can be more than just a weapon of war, the cutlass is an excellent example. For centuries, the cutlass was used by fighting forces throughout Europe as a short, one-handed stabbing and slashing weapon.
For many, the cutlass is best known as the sword of the pirates in the Atlantic Ocean during the 17th and 18th centuries. In a lesser-known role, it also was regularly used in agriculture throughout the Caribbean like the machete is today. In English-speaking Caribbean countries, the word “cutlass” is used to mean a machete.
In the modern era, the cutlass has left behind its fighting phase and is almost used exclusively as a ceremonial sword by several navies. However, its popularity endures among collectors and history buffs alike, thanks to its extensive use during the pirate era and the Age of The Sail.
What Is A Cutlass?
A cutlass drill on the HMS Wolverine , 1882 (Public Domain)
The cutlass is a one-handed, single-edged sword used for close-quarters fighting that was the evolution of naval sabers into a more compact, nimble short sword. While the edge does come to a fine point, the cutlass was designed for slashing and swinging at your enemies when fighting hand-to-hand.
This is why the sword was a popular seafaring weapon. With a slightly-curved blade, usually between 28-32 inches, the cutlass is adept in the close confines of a ship. The straight handle and clipped guards of most cutlasses protected your hand when in battle. Additionally, the cutlass was robust enough to tackle general maritime tasks like slicing through heavy rope or thick fabric like canvas or even wood. And its size made it the perfect weapon for the type of in-your-face fighting that would happen on the high seas.
On land, the cutlass wasn’t as dashing, mostly used to chop sugarcane and clear tracts of land in the rainforest in the New World. Though, the same qualities that made it a great fighting implement made it adept on the farm. The short, swooping blade allowed a great deal of force to transfer from the arm to the material with every swing.
Who Uses The Cutlass Today?
Today, the cutlass is used almost exclusively as a ceremonial sword. While it was at its most popular centuries ago, the cutlass was still a standard issue sword until around World War 2 before it became wholly ceremonial.
The British transitioned the sword to ceremonial duty in 1936, and the United States followed suit in 1949. Both countries incorporate the sword into military ceremonies today. The Brits issue cutlasses to naval chief petty officers. The United States also offers chief petty officers the ability to wear a cutlass with their formal dress for ceremonies and the like.
Can I Buy A Cutlass?
Absolutely. There are many companies making cutlasses today. While they may not be as pristine as the ones issued by the military, there are numerous companies making these types of blades.
Factory Cutlass Options
Cutlasses are still made today, but, in general, they aren’t built to the same combat standard as in centuries past. The vast majority of these swords are showpieces meant to be hung on the wall and start conversations. However, if you are a true lover of the Age of Sail, these swords more than fit the bill.
Windlass English Cutlass
This 30.5-inch sword from Windlass is an elegant modern Cutlass, and, for a fee, can be sharpened into a real, proper sword. As is, the high-carbon steel blade is hand forged and mated to a solid brass guard. You’ll really feel like Blackbeard with it in your hand.
The sword comes with a leather scabbard adorned with a brass tip and throat to up the visual appeal of the piece. All told, this is a high-quality replica of the cutlass that will get people talking at your next party and look great in your office or hanging on the wall.
MSRP: $190
Condor Naval Cutlass
The Naval Cutlass from Condor Tool & Knife is a more modern take on the classic blade. The first thing you notice about it is the black epoxy powder finish to the blade. We’re pretty sure pirates of the 18th century didn’t have powder-coating technology, but would have loved to have had the extra corrosion resistance on the high seas.
The blade checks in at 24 inches in length and is made from 1075 steel ground to a razor’s edge. Yes, this sword comes sharpened right out of the box for no extra fees. The smooth hardwood handle is triple riveted, and a powder-coated guard keeps your hand protected when holding the sword. A black welted leather scabbard fits snugly around the blade and keeps everything protected even if dropped.
While it certainly doesn’t look like a sword from the movies, it’s designed to be a true, proper modern cutlass.
MSRP: $148.49
Kult Of Athena Pirate Sword
Complete with a skull and crossbones etched into the scabbard’s throat, the Pirate Sword from Kult of Athena looks like it could have been taken from the set of any swashbuckling movie set.
The 22-inch blade is made from stainless steel and comes, according to KoA, moderately sharp out of the box. That means it might need a more refined sharpening at home if you’re looking for a razor’s edge. However, the blade itself is .16 inches thick, thin enough to slice well but thick enough to hold up to some wear if used for more robust cutting tasks. But be aware, the sword is classed as “decorative”, or for display only, so keep that in mind before playing out your high seas fantasies.
The cast metal handle is surrounded by a bronze-plated cup guard which features a pirate ship design. The black leather scabbard has a cast tip and throat to complete the look.
MSRP: $49
Kingston Arms Atrim Cutlass
The Kingston Arms Atrim Cutlass shows that not all collectible blades need to be centuries old. Made in the style of a naval cutlass, the Atrim utilizes modern materials and methods to make a truly remarkable sword.
The 9260 spring field falchion-style blade is hand forged and comes in a satin finish. At 25.75 inches it’s a bit smaller than some other cutlasses, letting it move more fluidly in your hand and taking up a smaller display space. The full-tang construction terminated with a stainless steel guard and pommel around a brown leather handle that provides a strong grip.
This is the most expensive sword of all the cutlasses showcased in this piece, and it’s worth every penny for the discerning, high-end collector.
MSRP: $432.95
Cold Steel 1917 Cutlass Sword
When it comes to collector pieces outside of auctions, Cold Steel’s 1917 Cutlass Sword is a prime example of what’s being made today. While it is designed for display and collection, the 1055 steel blade does come with a serviceable edge out of the box.
In terms of size, it’s exactly what you’d expect a cutlass to be. At just under 30 inches long and 37.6 ounces, it’s a nimble sword that will feel good to hold and wield when showing off all of its intricacies. The wood handle and blued steel hand guard complete the look, and the included leather scabbard keeps the sword looking classy even when put away.
MSRP: $289.99
APOC Survival Cutlass
This option is rated for proper use rather than display. That’s abundantly clear considering it comes with a MOLLE-compatible Kydex scabbard. That doesn’t come with swords meant to be hung on the wall.
The APOC is a tactical sword that has a 21.5-inch black oxide blade made from 9260 spring steel. The black G-10 handles complete the monochromatic look and provide excellent grip in myriad conditions.
At just under 2 pounds, this is a lightweight cutlass meant to be used as a survival tool out on the trail or in more intense outdoor situations. The blade is meant to slice, of course, and the edge comes to a fine point, making this a puncturing tool as well. Versatility is the name of the game in survival equipment, and, while a machete or shorter knife might be a better option, the APOC cutlass is built for the outdoors and to handle the elements.
MSRP: $169.95
Custom Cutlass Options
There are numerous people making custom cutlasses and other swords. Whether it is for the private use and display of an individual or to be used as props in movies, at renaissance fairs, or in other forms of entertainment, there are makers and smiths crafting modern versions of the centuries-old blade.
Even the popular YouTube Series Man At Arms: Reforged did an episode about the cutlass and showed multiple ways to craft them.
Tony Swatton
Swatton runs Sword & Stone in Burbank, CA and makes arms and armor for film and television. He, and his shop, were the star of the original Man at Arms series nearly a decade ago. He’s self-educated and has been making armor since he was 17.
The first movie his work appeared in was Hook in 1991, and since then his weapons have been seen on screen in more than 300 movies including massively popular films such as Pirates of the Caribbean, Batman, and Thor. He also designed the cutlass used in Assassin’s Creed 4.
David Lisch
Lisch makes custom knives and swords exclusively from damascus steel. His 26 years of experience in the field are seen in the intricacy of his mosaic patterns and one-of-a-kind blade designs. He’s made landscapes and sunrise designs on his blades.
An example of David Lisch’s damascus work.
His knives have won awards and he teaches classes in blacksmithing and knifemaking with his wife Andrea at their school in Yelm, Washington, about an hour south of Seattle.
Collecting Cutlasses
The cutlass is collected by all sorts: sword lovers, pirate aficionados and history buffs. Specialty dealers help these collectors find the pieces they are looking for, and it helps keep the cutlass alive and in public consciousness.
Additionally, cutlasses have made it to auction houses around the world, sometimes fetching as much as $10,000 before the hammer falls at auction houses like Morphy’s, Sotheby’s, and Rock Island.
In late 2022, the 1860 naval cutlass belonging to John H. Ferrell, a Congressional Medal of Honor recipient, went to auction at Morphy’s and sold for $14,760. The sale showed how, even today, the popularity of the cutlass continues to endure in a big way.
Vincent Silva’s Carver packs healthy cutting power in a compact package.
After Vincent Silva retired from the military, he came across HealingFlamesForge.org, a Tennessee-based non-profit blacksmith shop for veterans. He took to the hammers and hot steel quickly, which progressed into making knives. Creating a functional tool from a piece of steel became his goal, and the Carver is one result. It begged to be tested and I was only too happy to oblige.
Carver Light-Duty Cutting
For the first edge test, the knife aggressively sliced into graphing paper even though the paper was slightly limp from the humidity. I applied smooth downward pressure and it cut cleanly. This is a well-balanced little blade.
Full-length push cuts went swiftly through the cardboard. The handle aided in blade control while keeping cuts as even as possible.
Single-walled cardboard supplied the next challenge. Full-length push cuts went quickly. It was hard to keep my fingers out of the cutting zone if I went too fast. The handle aided in control of the blade while keeping cuts as even as possible (in the cardboard, not my finger). I could hear a small crunch sound as the edge parted the material.
Carver Medium-Duty Cutting
Next up: 8-ounce leather. The Carver zipped through it swiftly. The blade’s edge geometry is spot on for working leather. I used a push cut while skiving the material.
The Carver zipped through 8-ounce leather very quickly. The blade’s edge geometry is spot on for working leather. The author used a push cut while skiving the material.
I like to be ahead of the game during camping weather, so a good supply of fire sticks is always a must. The Carver produced nice, feathered curlicues in some pine. The handle shape made it easy to control the depth of the feathering. All cuts came out smooth with just enough curl.
Carver Heavy-Duty Cutting
The Carver might be on the small side but it can handle such large jobs as splitting wood. Using a dead-blow hammer, I repeatedly pounded the blade through seasoned hackberry. A nice pile of kindling was the result. The handle was comfortable throughout and the blade was just big enough to beat on the tip to split the wood completely. There was no damage to the blued finish or the edge. Nicely done, Vincent.
It was time for my favorite cutting medium, natural rope—in this case, half-inch sisal on a cutting board. The Carver crunched its way to 192 cuts before the edge started to slide. The handle created no hot spots. The gimping was a tad sharp for my thumb but great for ferro-rod use. This is one cutting little knife!
The knife is small but can handle such larger jobs as splitting wood. Using a dead-blow hammer, the author repeatedly pounded the blade through seasoned hackberry for a nice kindling pile.
It was back to the graphing paper for the final slice test. The blade still cut very well and lost only a bit of its aggressiveness.
To push things over the edge, I conducted a brass rod test to make sure the temper was done correctly. I could see the edge flex and return to true. Verdict: the heat treatment was spot on.
CHANGES To mee, the edges could be softened a bit more, especially on the spine gimping. However, the Carver is a very well-made EDC sheath knife that performs at a higher level. It’s a sweet little blade.
Carver Specs Maker: Vincent Silva of Iron Sapper Forge Blade length: 3.5” Blade material: 1095 carbon steel Blade grind: Flat Heat treatment: Differential Handle: Pinecone resin by @sappercsmwife (Instagram) Weight: 6.5 ozs. Overall length: 75/8” Sheath: Kydex or leather pouch Maker’s list price: $250
Consider four large kitchen knives, all under $80 each.
As you get older and entertain bigger gatherings, do you find yourself wanting to improve your culinary chops?
A little more blade may be just what you need to sharpen your prep time so you can spend more time enjoying your food than getting it to the table. Larger and more focused kitchen tools can indeed improve your efficiency and your proficiency as a gourmet chef as well.
The focus here is on large and/or specialized kitchen knives, specifically the different types and what they can do to make your job easier and your cooking better, each for under $80. Large cooking knives vary widely and we’re going to show you four variations. Keep in mind, most kitchen knives aren’t just for cutting meat but are for preparing fruit, vegetables and other items such as breading or crusts, too.
Utica Meat Dad Chef’s Knife
The Utica Meat Dad Chef’s Knife is for large cuts of meat, fruits and vegetables. It took half-inch medallions off a plump pork tenderloin for the sauté pan.
Meat Dad Chef’s Knife Specs Blade length: 7.54” Blade steel: 440C stainless Blade finish: Food Safe Black PVD Handle material: Orange G-10 Weight: 17” Overall length: 12.5” Country of origin: USA MSRP: $74.99
The Utica Meat Dad Chef’s Knife is a whopper with a blade belly 2.25 inches deep for carving the big stuff when needed and everyday slicing and dicing as well. The beefy orange G-10 handle helps maintain control on the wieldy blade for it all.
Though the test’s two chef’s knives—the Fox Knives Meat Slicer being the other—have meat in their names, they facilitate a much wider variety of meal prep tasks, including the slicing, dicing and mincing of a wide range of vegetables and other fare.
The Meat Dad is large enough to tackle a watermelon in a straight cut.
The Utica is large for a chef’s knife so we tested it on some heathy chores, such as cutting a nice, plump pork tenderloin into fat medallions for a tasty sauté. We also tried the Meat Dad out on a watermelon and, thanks to the stout blade, sliced it straight as an arrow from top to bottom. Sometimes you just need a large knife and the Utica tackles those requirements quite well.
Fox Meat Slicer Knife
Like many typical chef’s knives, the Fox Meat Slicer is capable of many functions. Wrote the author: “I used the knife for slicing small brown portobello mushrooms to add to an omelet. Note the sharp, crisp cuts—a sign the mushrooms were not prepared by an ordinary kitchen knife.”
Meat Slicer Specs Blade length: 7.8” Blade steel: UNI X59CrMoV15 stainless Blade finish: Fine satin Handle material: Black PP synthetic Weight: 3.75 ozs. Overall length: 12.4” Country of origin: Italy MSRP: $36.94
All chef’s knives are relatively long but not all have blades that can be tiring to use. The Fox Meat Slicer Knife is a much trimmer, more svelte example. A large Italian cutlery company with an impressive presence in the USA, Fox offers a strong group of knives in its Due Cigni Coltellerie line.
One of the group is the Meat Slicer, a long chef’s knife with a slim profile sporting an extended, slender drop-point blade only .12-inch thick. It comes with a gently curved handle that has just enough drop at the base to protect your fingers during use.
The Meat Slicer is more adept at less cumbersome tasks of both the meat and vegetable variety. We first used it on a couple of smoked sausage links, cutting roughly 3/16-inch slices down the length of each for an omelet. The knife performed quickly and with ease.
The Fox Meat Slicer is excellent for most meals that don’t require cutting thick slabs of meat or large fruit and vegetables. It made quick work prepping smoked sausage.
To add a little flavor, we turned to some portobello mushrooms. Taking a handful, I trimmed the stems off and sliced them up one by one in a jiffy. The German steel performed very well and the handle was the most comfortable of the test lot.
A.G. Russell 6-inch Boning Knife
The A.G. Russell relieved the chicken breast of its hard-shell-bone understructure pronto. “Fowl such as chickens retain their juices and flavor much better when cooked on the bone,” the author noted. “Here the chicken breast is removed, sliced and ready to eat.”
The A.G. Russell 6-inch Boning Knife just might be your go-to counter slicer for a myriad of kitchen duties. While its name is designated for separating meat from bones, the A.G. Russell can perform a myriad of duties such as trimming, slicing and dicing both meat and veggies. Some even clean their afternoon catch with it as it is closely related to a fish knife. The blade is super thin and the piece is very lightweight.
The A.G. Russell got the most tedious work out of the foursome due to the nature of the beast. Fortunately, chickens go through extensive steps of processing before average folk ever set eyes on them. Whether fried, barbecued or roasted, the best way to keep a chicken breast moist is with the skin, breast meat and bone structure cooked together.
After cooking the bird, use the sharp cutting tip to cut the area around the breast skin so it can be removed with the meat. Next, peel the skin back and slowly work the blade between meat and bone structure and slowly use the fingers of your other hand to peel the entire breast off with the skin on. Slice and eat!
The A.G. Russell Boning Knife has a thin, sharp blade very much akin to a fish knife and can be used for other types of work around the kitchen. The author used the razor-sharp blade to cut off the tails of shrimp for a cocktail.
The Boning Knife, like the others, is handy in other ways as well. You can slice small veggies and fruits, trim fat and do all sorts of clean-up chores to make food more presentable.
Ontario Old Hickory 76 7-inch Cleaver
Cutting thick carrots across the grain can be tough on many kitchen knives but was easy for the Ontario Old Hickory 76 Cleaver.
Old Hickory 76 Cleaver Specs Blade length: 7.5” Blade material: 1075 carbon steel Blade grind: Flat bevel Blade finish: Brushed Handle material: Wood Weight: 10 ozs. Overall length: 12” Country of origin: USA MSRP: $30.50
We’ve saved the big gun for last: the Ontario Old Hickory 76 7-inch Cleaver. There’s something to be said for the simple, matter-of-fact Old Hickory edged tools. Maybe it’s the “If it ain’t broke, don’t fix it” attitude—and I like it! The blade has a horizontal pattern pressed into it, a hole for hanging in the upper lead edge, and an Ontario Knife Co., Tru Edge, Made In U.S.A., sword logo stamp in the top center. The blade climbs upward toward the tip at its spine and the cutting edge has a gentle curve to it.
When you need a heavy hand and finesse is no object, the cleaver will get the job done. We used it for cutting some tough-as-nails carrots with no problem. The same went for hard sausage. There’s no sense in dulling a sharp knife blade on hard, tough foods when a cleaver can cut them with haste and look for its next challenge.
Chubs of hard summer sausage are what the Old Hickory 76 lives for.
Old Hickory blades are the kind of “git ’er done” kitchen knives and tools that take your tough challenges on their back and never cry uncle. My family grew up with Old Hickory blades and I recommend keeping them around the kitchen when tough times call for tough tools.
Final Cut
There you have it—four different ways to make your kitchen more useful without breaking the bank. If you’re ready to expand your culinary universe, look no further than these useful, able kitchen helpers.
Designed with Spartan Precision Equipment, CRKT’s backcountry-ready Altai pairs 14C28N steel with an integrated fire rod and ceramic sharpener.
CRKT has teamed up with the shooting platform specialists at Spartan Precision Equipment to introduce a new backcountry fixed blade: the Altai. Named after Spartan founder Rob Gearing’s hunting excursions in Mongolia’s Altai Mountains, the knife integrates purpose-built field features directly into the cutting system and sheath setup.
Tailored for Field Processing
The Altai centers around a 3.53-inch plain-edge blade fashioned from 14C28N stainless steel. To withstand harsh outdoor environments, the steel is treated with a protective ceramic coating designed to bolster toughness and resist corrosion. The 0.13-inch thick blade is sized specifically to maintain maneuverability and control during game dressing, while jimping along the finger choil and spine provides positive tactile traction.
The knife features glass-reinforced nylon (GRN) handle scales textured with a carbon-fiber pattern, secured over custom pins bearing the Spartan head logo. High-visibility orange highlights run along the build, helping users spot the knife easily in dim light or deep cover. At the butt end, a ringed pommel allows for a fast draw—even when wearing thick gloves—and includes a lanyard hole for additional retention options.
Built-In Fire and Maintenance Kit
Rather than serving as a standalone cutter, the Altai incorporates essential survival and care tools into its carry rig. The knife’s spine includes a dedicated striking notch configured to work with an included magnesium alloy fire rod. For touch-ups during long trips, a ceramic sharpening rod is also housed directly alongside the blade.
Both maintenance accessories stow in the included molded thermoplastic sheath. Reflective orange paracord is used for the main lanyard as well as the pull tabs on the fire and ceramic rods, ensuring high visibility when working in low-light conditions.
At 8.0 inches in overall length and a weight of 3.6 ounces, the Altai offers a complete backcountry processing and field-maintenance package in a compact carry footprint.
Mosaic Damascus Can Be Made Numerous Ways, And These Master Smiths Are All Putting Their Own Spin On The Craft.
The many moods of mosaic damascus provide the bladesmith and custom knifemaker with an ever-changing form of artistic expression. The possibilities of a new pattern, a different look, and yet another lasting impression are endless.
For several makers, mosaic has become a signature steel in their presentations, and these imaginative artists are pushing the envelope in an already dazzling array of motifs for blades and knife fittings.
Kelly Vermeer-Vella
Kelly Vermeer-Vella said she initially called the mosaic damascus of her fighter Riptide because it looks like “calm waters, but also because the forging process is pretty brutal. So, now I call that process ‘ripping it!’” Blade and overall lengths: 7.5 and 12.5 inches. At press time the knife was available through Arizona Custom Knives for $3,800. (SharpByCoop knife image)
In her Riptide pattern, American Bladesmith Society Journeyman Smith and past Forged in Fire champion Kelly Vermeer-Vella provides a great example of the new frontiers being explored with mosaic damascus.
“It’s initially called that because it looks like calm waters,” she commented, “but also because the forging process is pretty brutal. So, now I call that process ‘ripping it!’ Sometimes I win and sometimes I make hunters!”
Kelly showcases the Riptide pattern on her 12.5-inch fighter with a 7.5-inch blade and mammoth ivory handle sporting a long, modified “S” guard.
“I really enjoy swooping forged guards that complement the curves of the blade and handle. And I love mammoth ivory, so I make a lot of frame handles,” she added. “I think the best-looking frame is in a low-layer twist, 25 layers or so.”
The Vermeer-Vella mosaic involves a commitment to hard work to produce the desired results.
“The pattern is not san-mai,” she revealed, “rather, different layer counts of stacked W’s with heavy 1075 steel on the edge. The wing effect comes from forging. I push and pull the pattern with a hand hammer and forge to shape so that the pattern flows with the edge.”
The blade material is the 1075 carbon steel, which appears as the dark areas, and 15N20 nickel alloy, which shows as the grey, shiny areas. “I etch in 3-to-1 ferric chloride and also do a coffee etch,” she added. Her power hammer is an Anyang 88 and she uses a Riverside 24-ton press.
Jack Rellstab
Jack Rellstab said he wanted the blade of his Western Chef’s Knife to “look alive.” As he noted, “My idea was with the taper in layers to give it an organic look that appears as if the elements are actually growing.” Thus, the pattern’s name of Frogs and Flowers seems most apropos. His price for a similar knife: $2,600. (SharpByCoop image)
Like Vermeer-Vella, Jack Rellstab is an ABS journeyman smith who enjoys the creative process of forging mosaic damascus. His Western Chef’s Knife brings a robust profile to life in a mosaic pattern called Flowers and Frogs.
“The pattern is one of my styles of W’s explosion,” he noted. “I started the original billet with the layers of both 1080 and 15N20 getting progressively thinner from one side of the billet to the other. After using square dies to resquare the billet for W’s, I drew it out with a taper so the W’s would get tighter towards the end. Then I did a restack and a four-way to finish it. So, the steel is 1080 for the dark portion and 15N20 for the bright.”
The handle is amboyna burl, bronze and G-10. He says the grip is designed around most Western-style kitchen knives on today’s market, though the belly/underside might be a bit shallower.
“With this mosaic pattern, I wanted the knife to look alive,” he offered. “My idea was with the taper in layers to give it an organic look that appears as if the elements are actually growing. I used a 165-pound hammer belonging to New West Knifeworks, and I also used their Anyang hydraulic press for resquaring.”
Jack began his bladesmithing journey with mosaic damascus by watching a YouTube video, and then let his imagination kick in to develop the exciting pattern that is sure to generate conversation in any kitchen.
Will Stelter
The Serpentine Multi-bar Santoku by Will Stelter sports a mosaic damascus pattern of the same name. He used 1080 and 15N20 steels for the pattern-welded twisted bars and Cruforge V for the edge. The Cruforge V etches darkly, and its wear resistance and high working hardness make it ideal for culinary knives. Blade and overall lengths: 5 7/8 and 10.75 inches. His price for a similar knife: $3,500. (SharpByCoop knife image)
The Serpentine Multi-bar Santoku by ABS Journeyman Smith Will Stelter sports a mosaic damascus pattern of the same name. The handle is ivory paper Micarta®. He used 1080 carbon and 15N20 nickel-alloy steels for the pattern-welded twisted bars and Cruforge V for the edge. The Cruforge V etches darkly, and its wear resistance and high working hardness make it ideal for culinary knives.
“I started by forging up 28 layers of W’s,” he recalled, “and then worked that billet down to a half-square twisting stock. I twisted three bars right hand and two bars left hand, lining up my twists as best I could before forge-welding them together. After they were stuck, I forge welded on a solid Cruforge V edge bar that was around 40 percent as wide as the multi-bar billet, but the same thickness. With my final stock stuck together, I then laid out and cut away several three-quarter-inch-deep grooves or divots from the profile of the rectangular 2-inch wide bar, which still left Cruforge V on the edge, and two full twisted bars at the thinnest parts of the patterned area on the spine.
“I then flattened down the billet, which took the previously straight layers and gave them the bold ‘serpentining’ that came out in the blade. I then forged my blade to shape and forge welded on some of the base W’s stock that I twisted from as bolster material. This is a very similar technique to how the classic ‘River of Fire’ pattern is done, but with a different base pattern other than the usual feather pattern.”
Will used his 1924 400-pound ram Beaudry hammer to do the majority of the forge welding and a twisting machine to twist the five bars. He learned his pattern-welding technique and the ability to visualize the way the steel moves from bladesmith Salem Straub, crediting Straub with teaching him how to design patterns “with intentionality behind them.” The pattern itself is sole authored by Stelter, who has done some serpentine multi-bar patterns prior to the subject piece. However, this was his first attempt with a monosteel-edged bar.
“The serpentining is purely aesthetic,” Will said. “It’s meant to give a bold line for the eye to dance down rather than the straight, more classic intersection of the edge bar that is normal for a composite construction. This also means that from far away you see an interesting pattern, and then when inspected up close the explosions of the twisted W’s really pop out, which gives the overall piece an interesting level of depth.”
Will considers this particular mosaic “an intermediate-level pattern, easy to try, though somewhat difficult as well. The most challenging part is building a high-quality multi-bar pattern with adequate layer density and well-matched twists. The rest of the pattern is fairly simple.”
Brent Stubblefield
Brent Stubblefield’s integral chef’s knife has an 8-inch blade of his shimmering Crossroads mosaic damascus, and a stabilized Hawaiian koa wood handle with mammoth tooth spacer. Overall length: 13 inches. His price for a similar knife: $1,500. (SharpByCoop image)
At the Join or Die Knives Forge in Richmond, Virginia, Brent Stubblefield hammered a beautiful blade in his Crossroads mosaic pattern—and did so with multiple techniques.
According to Brent, “There is the initial damascus forging, crushed W’s, twisting, four-bar-squaring welds, ferry flip tilting, edge bars, and a ‘fish mouth’ tip to make the edge bars meet. There are multiple elements that are forged on the edge or corners to manipulate the pattern, and finally the knife shape and integral bolster are forged to shape.”
The mosaic is comprised of 1084 and 15N20 steels, with the 15N20 appearing as a silver white on the blade while the 1084 blackens with a ferric chloride etch.
“The shapes in this pattern reflect a desire to incorporate all the different techniques of mosaic damascus making I have learned over the years,” he explained. “I’m always trying to find a way to create never-before-seen patterns in order to add something totally new to the American bladesmithing tradition.”
Stubblefield used an Anyang 88 power hammer and homemade 30-ton press to create the Crossroads mosaic. A Bridgeport mill was helpful in the squaring-up process and flattening pieces for rewelding. A Miller welder assisted in tacking materials up before they went into the forge, while an Evenheat kiln and Broadbeck Ironworks grinder were key tools in the process as well.
“Although I did not have any single mentor,” Brent mused, “many knifemakers have gone out of their way to share tips and tricks with me. While they didn’t teach me directly, [bladesmiths] Mareko Maumasi and Salem Straub have been very generous with sharing their processes through social media. I certainly have referenced them among others.”
Stubblefield continues to challenge himself as his career advances, and he sees no slowdown in the creative process. “This knife is very difficult to do simply because the higher number of forge welds create more opportunities for failure,” he reasoned. “Any complex damascus blade is actually just many simple techniques combined together. The hardest part for me is understanding how manipulating the pattern early in the process will affect the outcome, and visualizing the end pattern.”
