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Knifemaking

Knifemaking is the building of a knife, which includes the blade, handle and other accouterments. Blades are made by either removing metal from a steel blank via a grinder – known as stock removal – and the forging to shape of hot steel into a blade in the process known as bladesmithing. Other parts, including bolsters, guards, pommels, etc., are needed to complete the finished knife.

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Secrets Of The Shop: Steve Schwarzer & Bob Terzuola

Jim Hammond
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Secrets Of The Shop: Steve Schwarzer & Bob Terzuola

Schwarzer’s blister busters and Terzuola’s effective efficiencies.

Editor’s Note: Jim Hammond has been a full-time knifemaker since 1977 and a member of the Knifemakers Guild since 1978. He was the first maker to work with CRKT and has many well-known designs to his name. This is the first of an ongoing column in which he uncovers the tightly held secrets of master knifemakers.

Welcome to Secrets of the Shop, where we dive deep into specific techniques and tips highlighted in the work of premier makers and knife smiths. While trade secrets often imply guarded formulas, for knifemakers, they are keystone discoveries that hone processes and perfect craftsmanship. This column seeks to turn these unrevealed secrets into shared solutions.

Popping Blisters

A veteran ABS master smith and BLADE® Magazine Cutlery Hall of Fame® member, Steve Schwarzer is probably best known for his pioneering work in the canister method of forging mosaic damascus. He is considered one of the finest instructors and ambassadors of the forged blade and of mosaic damascus, teaching at seminars and hammer-ins on the subjects for decades in Europe, South Africa, the USA and elsewhere.

During welding, a cold shut—a spot of incomplete merging of steel—can produce a trapped-gas bubble known as a blister. The spots where these void occur heat at different rates than the surrounding material and turn black. Often caused by worn and cupped dies, these blisters typically form along the billet’s perimeter.

Steve’s solution to addressing blisters is as follows:

  • Release the Gas: Punch a hole directly into the blister.
  • Flux and Forge: Drop borax into the hole and use a small rounding hammer to forge the area, pressing air out of the seam to recreate a uniform weld.
  • Refinement: Check the surface for flatness. Steve utilizes belt and stone surface grinders to achieve trued flats and maximize uniform contact.

To prevent blisters, Steve welds the edges of a billet before the center using a radiused fullering die. Going this route is less prone to create blisters than a flat die, though more apt to distortion. This technique was vital when Steve and Neil Kamimura created a million-layer billet that was folded rather than stacked, requiring the resolution of numerous small cold shuts.

Mosaic On A Budget

Schwarzer uses what he calls a “tiling” process with his canister damascus, sawing off the end to expose the image, and forge-welding them side-by-side to maximize the visual impact across the blade’s surface. (Steve Schwarzer image)
Schwarzer uses what he calls a “tiling” process with his canister damascus, sawing off the end to expose the image, and forge-welding them side-by-side to maximize the visual impact across the blade’s surface. (Steve Schwarzer image)

While CNC and EDM equipment can create intricate designs, a more affordable approach involves the sintering process of canister welding damascus, a method originated by Steve and Daryl Meier.

Steve’s canister process is as follows:

  • Composition: A square canister is preferred to maintain the image’s shape using flat dies. Content determines the pattern—solid metals form the primary image, while powder fill creates the background.
  • Preparation: Both ends must be welded shut to exclude oxygen.
  • Release Agents: To free the billet from the canister, Steve uses white spray paint; the titanium dioxide acts as an immediate release agent, oxidizing upon heating. Other options include White Out and stainless-steel foil.
  • Sintering: Steve recommends a soak time of at least 30-plus minutes. Expect a size reduction of roughly 30 percent as micro-spaces between particles collapse.

To expose the end-grain imagery, Steve uses what he calls a “tiling” technique. Band sawing sliced off the billet exposes the faces of the pattern. Then, forge-welding them side-by-side, he maximizes the visual impact across the blade’s surface. Note flat grinds are customary with this process, as deep grinding can distort the integrity of the imagery, especially with twisted materials.

For New Makers

Steve offers two foundational tips for those entering the craft. First bit of advice Schwarzer makes is to, “Avoid unknown materials, even if they’re free.” Without knowing the composition of “mystery steel,” you can never accurately repeat your results. He also suggests makers define their own path, saying, “Don’t chase anybody else’s dreams. Chase your own.”

Cutting Coupons

Bob Terzuola was a pioneer in using lasers and waterjets in his manufacturing process. Among the efficiencies he incorporated in using these tools was cutting what he calls “coupons.” These are simply uniform blade blanks and liner sections. Keeping a load of these on hand speeds up the manufacturing process, while maintaining the integrity of the knife. (Bob Terzuola image)
Bob Terzuola was a pioneer in using lasers and waterjets in his manufacturing process. Among the efficiencies he incorporated in using these tools was cutting what he calls “coupons.” These are simply uniform blade blanks and liner sections. Keeping a load of these on hand speeds up the manufacturing process, while maintaining the integrity of the knife. (Bob Terzuola image)

Known as the “Godfather” of the tactical folding knife, Bob Terzuola has been a full-time maker since 1980 and was inducted into the Cutlery Hall of Fame in 2023. His longevity in the craft stems from a blend of old-school design and modernized production efficiency. Terzuola was a pioneer in the mid-’80s, becoming the first maker to utilize laser cutting for components. Today, he uses waterjet cutting to create generic rectangular blade blanks and liner sections, which he calls “coupons.”

For the blade blanks, Terzuola profiles the rear area with the lock face, thumb ran and pivot/stop pin holes (roughed to 80 percent diameter). The rest remains rectangular, allowing him to incorporate any pattern with minimal grinding. Bob has his CPM 154 stainless steel blanks commercially surface ground to 0.135-inch before heat-treating them himself to HRC 59. For the liners—0.080-inch titanium in our discussion—the coupons are left square, containing only the pivot hole and the horizontal slot for the locking spring arm.

Notably, Terzuola grinds his blades after they are hardened. He argues grinding annealed steel can lead to warping during heat treat and causes the belt to gouge material. Grinding hardened steel, by contrast, is like slicing meat with a razor blade rather than digging dirt from a hole. Despite these modern efficiencies, he said he remains a “pencil-and-paper guy,” eschewing CAD for hand-drawn patterns to maintain design commonality.

Finishing Simplified

Despite modern efficiencies Terzuola has incorporated into his manufacturing process, he remains traditional in his designs. That is, he avoids CAD, instead using pencil and paper to hand-draw all of his knives. (Bob Terzuola image)
Despite modern efficiencies Terzuola has incorporated into his manufacturing process, he remains traditional in his designs. That is, he avoids CAD, instead using pencil and paper to hand-draw all of his knives. (Bob Terzuola image)

Bob’s finishing process for CPM 154 is remarkably lean. He utilizes a 90-durometer smooth-face rubber contact wheel and a simple two-belt sequence. First, he does a rough grind with an 80-grit ceramic belt, then finishes with a 3M Trizact A16 (1,200-grit) belt.
He specifically avoids 60-grit belts, noting that their mesh size is twice as large as 80-grit, creating scratches that are twice as deep and significantly harder to clean up. To ensure blade-lock longevity, he now uses a heat-treated 440-C stainless steel insert in the titanium spring arm. This provides a steel-on-steel lockup, eliminating the wear issues common with titanium.

For New Makers

Terzuola encourages beginners to find their own niche and not get locked into a single model. He emphasizes mastering the fundamentals with hand tools: learn to tap holes, use files and sharpen twist drills. He and I agreed, new makers should also gain proficiency with mills, lathes and surface grinders to be old-school efficient rather than purely CNC-reliant.

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Custom Cleavers That Have Culinary Chops

Mike Haskew
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Custom Cleavers That Have Culinary Chops

Four custom makers push the boundaries of the tried-and-true cleaver.

An inclination toward the kitchen and a desire to design and deliver cutlery used on a regular basis has spurred a number of custom knifemakers to try their skill with the cleaver. It’s a staple in most kitchens and its uses are as varied as the food prepared there.

Robert Wayman of Middleburgh, New York, sees his cleavers as complementing years of food preparation. “I’ve done a lot of my own food processing, and I spent several years in commercial kitchens when I was younger,” he commented. “So, I’ve always had an affinity for culinary knives and especially cleavers. The cleaver is such an iconic blade. I love to make everything from heavy-duty butcher cleavers to medium-duty kitchen cleavers, Chinese cleavers and lighter-duty veggie cleavers for the kitchen.”

Robert’s featured cleaver is 14 inches in overall length with an 8-inch blade of pattern damascus go-mai five-layer steel. The core is a 100-layer random pattern damascus made of 1084 and 15N20 high-carbon steel and a layer of nickel and matching damascus cladding. The handle includes a damascus collar, stainless steel and G-10 spacers, crosscut carbon fiber, green malachite and blue coral accents, stabilized amboyna burl and a damascus butt cap with stainless mounting pins inset with blue coral framed with green malachite.

“I packed a lot into that one,” Wayman smiled. “As a maker, I’m all about sole authorship. I make all of my own high-carbon damascus steel in-house, and a cleaver provides a great opportunity to showcase that steel. One of my favorite things to forge is a large cleaver with an integral bolster.”

Wayman sees large blades, such as those associated with cleavers, as inherently challenging, while making a task-specific blade, such as a cleaver, adds another layer of complexity. Although they are labor-intensive and involve a lot of time in the shop, performance remains the key.

 “Overall weight needs to be taken into consideration, as well as how that weight is distributed for the style cleaver you are making,” Robert advised. “Ergonomics is an important consideration for any knife or tool, but especially for kitchen cutlery. Whether it’s in a professional or home kitchen, you’re making a handle that a chef or cook could use for hours of food prep on any given day. So, it must be comfortable.”

Edgy Ebony

Having served time in professional food service, practical utility is never far from David Jacobson’s mind. However, he isn’t afraid of adding some flourish to his creations, such as the gold-inlay signature near the spine of his mosaic damascus bladed and ebony scaled cleaver. (SharpByCoop image)
Having served time in professional food service, practical utility is never far from David Jacobson’s mind. However, he isn’t afraid of adding some flourish to his creations, such as the gold-inlay signature near the spine of his mosaic damascus bladed and ebony scaled cleaver. (SharpByCoop image)

David Jacobson’s integral 13-inch cleaver with ebony handle scales sports an 8¼-inch mosaic damascus blade of 1085 and 15N20 steels and a gold inlay signature—his first such accent. He used brass bolt pins to finish the ebony scale attachment.

“I love cooking and making cool chef’s knives and kitchen tools,” Jacobson related from his Felton, California, shop. “Edge geometry for chopping and balance are challenges, and fullers are nice when slicing vegetables for food release. Cleavers are not only for the kitchen. They are great for large fish processing at the dock, chopping through bone and restaurant back-alley butchering. The wide blade shows off the many designs in the damascus steel, and I chose a traditional profile for this particular cleaver. I’ve always liked a black handle with big brass pins—old school.”

Cutting Mustard

Given the amount of steel and the need to pay attention to minutia is what Bill Tyc figures steers most makers away from cleavers. Tyc achieves an intricate pattern on his cleaver-chef’s knife set through a simple mustard patina, but applied with a straight edge for a pattern he calls “Lines of Insanity.” (SharpByCoop image)
Given the amount of steel and the need to pay attention to minutia is what Bill Tyc figures steers most makers away from cleavers. Tyc achieves an intricate pattern on his cleaver-chef’s knife set through a simple mustard patina, but applied with a straight edge for a pattern he calls “Lines of Insanity.” (SharpByCoop image)

The pairing in Bill Tyc’s featured ensemble is stunning in its presentation. “The cleaver as well as the chef’s knife are made of 52100 high carbon steel from the NJ Steel Baron,” he remarked. “The handles are stabilized spalted tamarind from Wood Dynamics fastened with brass Corby bolts. The pattern on the steel is a mustard patina done with a ruler edge, hence the name “Lines of Insanity” pattern. The cleaver is 11½ inches overall with a 6¼-inch blade. It’s 3 inches tall and ¾ inches at the heel. I felt the spalted lines of the tamarind wood would look perfect with the mustard patina.”

Tyc, who resides in Waterbury, Connecticut, remembers making kitchen knives that did something no other creations had generated. He got immediate feedback from users.

“In fact, the first ‘kitchen’ knife I sold was a cleaver at the Mystic Knife Show in Connecticut,” Bill remembered. “A gentleman circled the floor three times, every time touching a cleaver I had on the table. Last pass, he picks it up and just says, ‘I’ll take it.’ My wife and I look at each other with a thumbs up, and off he goes. Well, the following year, the gentleman comes into the show, right up to my table, and says, ‘Last year I bought a cleaver from you.’ The wife and I again look at each other because we most certainly remembered. He says, ‘I have so much fun using that cleaver every day!’ I reached across the table, shook his hand and said, ‘I’ve been waiting 20 years to hear that! I could pack up and go home, I feel so good.’”

According to Tyc, many custom knifemakers shy away from cleavers because they require a lot of work. At just about any knife show, only a relative few are seen for sale. But he adds cleavers’ utility far exceeds their supposed kitchen niche, pointing out they are handy for camping, survival exercise, yard work and bushcraft as well.

“The most important things are balance and weight,” Bill observed. “A knife used as often as a kitchen knife or cleaver has to feel good in the hand, not just initially, but long term. You may find yourself using your kitchen knives for many hours through the week. You want it to be comfortable, not a labor.”

Veggies Beware

One of the unique advantages of the cleaver, Dan Tomplins points out, is the large canvas it allows for the steel. In the case of his nakiri—vegetable cleaver—its 81/2-inch copper mai blade can’t help but catch the eye, particularly with the steel’s blacked-out finish enhancing the patina'd copper. Note too, the hybrid octagonal/western-style handle made from amboyna burl. (SharpByCoop image)
One of the unique advantages of the cleaver, Dan Tomplins points out, is the large canvas it allows for the steel. In the case of his nakiri—vegetable cleaver—its 81/2-inch copper mai blade can’t help but catch the eye, particularly with the steel’s blacked-out finish enhancing the patina’d copper. Note too, the hybrid octagonal/western-style handle made from amboyna burl. (SharpByCoop image)

In 2016, Dan Tompkins began making knives, and three years later, he started Evolution Cutlery in Highland, New York. His kitchen knife work began simply because he wanted to make cutlery used on a daily basis, and his cleaver immediately attracts attention.

“The big square profile is a great canvas to show forging skills, especially if using mosaic damascus. It allows a lot of room to see the details in the patterning,” said Dan. The subject steel is Baker Forge copper mai with a blacked-out finish and layers of patina’d copper in the nakiri, or veggie cleaver, design. The handle is Tompkins’ hybrid octagonal/western style made from amboyna burl, heirloom fit to a copper and G-10 bolster. The cleaver blade measures 8½ inches, and the overall length is 13 inches.

“One challenge in making cleavers is getting the edge geometry perfect for the intended purpose,” explained Dan. “There are many different types of cleavers, so the proper geometry is an important consideration. Heavy-duty blades require a heavy convex edge, while veggie cleavers are best with a laser-thin edge. When it comes to kitchen knife ergonomics, not only do you have to have a good feel in the handle’s shape and contour, but you also have to have proper balance to make the knife comfortable to use all day. While cleavers will almost always be slightly blade heavy in balance, they should still be balanced not far in front of the handle … Balance can make a light knife feel heavy or a heavy knife feel light. In my opinion, even a heavy knife with proper balance is far more comfortable to use than a light knife with improper balance.”

 Tompkins sees the cleaver in action in varied settings, not just the kitchen. Camp chores like chopping wood or preparing food outdoors can be handled easily with a cleaver made for such adventures, and he makes the cleaver to fit the anticipated tasks.

Versatility is readily apparent in these custom cleavers, and their functionality is in lockstep with good looks driven by their makers’ creativity.

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Custom Gallery: Customs That Demonstrate Martial Mastery

BLADE Staff
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Custom Gallery: Customs That Demonstrate Martial Mastery

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

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

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

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

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

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
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 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:

50 Years Ago In BLADE: Big Bucks Bowie

BLADE Staff
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50 Years Ago In BLADE: Big Bucks Bowie

Harvey McBurnette etched his name in high-dollar knife sales.

Harvey McBurnette of Piedmont, Alabama, landed in the July-August issue of the 1976 American Blade for somewhat patriotic reasons. Somewhat, because the lead of Harry K. McEvoy’s exposé on the maker was McBurnette’s celebrated Bicentennial Bowies. But there’s more to the matter than a simple commemoration of the nation’s birthday in steel.

McEvoy hooks readers by showing what the artistically talented knifemaker’s work commanded back when your dollar went a long way. In 1976, the exact sum was $4,500. As McEvoy wrote, “[O]ne of his fabulous, hand-crafted Bicentennial Bowie knives appraised at that substantial figure after he had sold the weapon to a collector for $1,300.”

The lead image of the profile on Harvey McBurnette shows him studying his original knife design and free handing it to the steel. The maker had a strong artistic streak and was known, in part, for the embellishments he etched onto his knives.
The lead image of the profile on Harvey McBurnette shows him studying his original knife design and free handing it to the steel. The maker had a strong artistic streak and was known, in part, for the embellishments he etched onto his knives.

For context, that’s roughly $26,000 in today’s dollars. What likely made the run of 76 bowies desirable was McBurnette’s unique system of adorning the knives—etching. This system, seen on many of his knives, was a very conscious choice on the maker’s part, as the story reports, serving to differentiate his work from other custom craftsmen of the day.

“I wanted to do something unique, or at least different, with my knives,” McBurnette was quoted as saying in the article. “And since I was an artist I thought if I engraved or etched my blade, I would add a touch I felt was needed to make them stand out. I chose the art of etching because there were a few other knife makers who engraved their knives. Besides, even a master engraver cannot do what an etcher can do.”

McBurnette’s Bicentennial Bowies had quite a motif etched on either side of their D2 tool steel blades. On one side of the 16.25-inch knife is an image of the Liberty Bell, and on the other a battle scene depicting Bunker Hill. The images are the same on all 76 knives, and 75 of them had elephant ivory handles. The knife appraised for the then astronomical sum did differ; the No. 1 of the series was a prototype with a walrus ivory handle.

More Knife History:

Pull Of The Push Dagger

Mike Haskew
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Pull Of The Push Dagger

Master smiths explore the symmetry, skill and survivalist roots of a classic.

It’s part adventure with a bit of notoriety and a dash of creativity. For the modern custom knifemaker, several styles are brought to life with history in mind. And the push dagger is one of them.

Maybe seldom seen, but always intriguing, push daggers trace their lineage to a bygone era when self-defense at the card table or on the street meant quick deployment from a vest pocket. For sure, that perspective spurs some custom makers to insert the push dagger into their repertoire while the stylized and subtle blend of blade and handle combine for a unique test of shop skill.

“They’re a backup tool,” explained ABS master smith and BLADE Magazine Cutlery Hall-of-Fame® member Steve Schwarzer. “They were typically carried in the 1700s and 1800s along with a one-shot pistol. After that shot, the push dagger was the next position. It’s been around for a long time as an extension of your arm with a blade, and it is hard to take away from somebody that is skilled in its use.”

Schwarzer’s featured push dagger with stag handle and evocative faces carved on both ends is 5¾ inches long with a 3¾-inch blade of mosaic damascus steel. He has actually made two push daggers in this style and designed another for Benchmade about 20 years ago. “For me, they’re fun, and that’s why I like to make them,” he commented. “I’ve always had a fascination about them and adapted my martial arts background to training with them. The design traditionally is with a very short blade, and in martial arts, it has to do with the alignment of the hand and arm bones, along with the shape of the blade, which is double-edged traditionally. Everything in nature is curved for an effective cutting surface.”

Harvey Dean Tejas

Why a push dagger? Harvy Dean (inset) puts it succinctly, “They’re just cool.” That certainly holds true for his Tajas push dagger, with an elegant feather damascus blade, 24k gold raised vine work and a fossilized walrus tusk handle. At 16 1/2 inchces in length, Dean gave himself plenty of knife to decorate. (SharpByCoop image)
Why a push dagger? Harvy Dean (inset) puts it succinctly, “They’re just cool.” That certainly holds true for his Tajas push dagger, with an elegant feather damascus blade, 24k gold raised vine work and a fossilized walrus tusk handle. At 16 1/2 inchces in length, Dean gave himself plenty of knife to decorate. (SharpByCoop image)

Legendary master smith and Hall of Famer Harvey Dean enjoys the historical aspect as well. “They’re just cool,” he offered. “A lot of people made them back years ago, and there was the idea of concealing them in the vest. Some were made with nickel-silver scabbards and called lapel knives because they were pinned under the vest or coat lapel.”

Dean’s pictured Tejas push dagger is a departure from standard sizing, with an overall length of 16¼ inches, with an 11-inch ladder pattern damascus blade and handle of fossilized walrus ivory. But then, everything is bigger in Texas.

“I’ve always liked [master smith] Larry Fuegen’s push daggers, and his work has had a lot of influence on mine,” Harvey said. “You really make them like any other knife, and I usually do around two or three a year. I like to use ivory and damascus and a stag handle is next up. I don’t do many plain ones, and most of mine are with two-piece handles. As far as marketing is concerned, you’ve got to have that special person who likes them–but they do usually sell quick.”

Hawks Nest Custom Push Talon

Matt Hunter (inset) has always had a thing for concealed carry knives, but admits his mother-of-pearl handled push daggers were his first crack at the style of knife. Angular and wickedly attractive, the Nichols Slither Armor Core stainless damascus daggers were designed as a matching set with his HawkWing knife, also pictured. (SharpByCoop image)
Matt Hunter (inset) has always had a thing for concealed carry knives, but admits his mother-of-pearl handled push daggers were his first crack at the style of knife. Angular and wickedly attractive, the Nichols Slither Armor Core stainless damascus daggers were designed as a matching set with his HawkWing knife, also pictured. (SharpByCoop image)

Damascus blade, mother-of-pearl handle and variations on the push dagger theme highlight Matt Hunter’s work at Hawks Nest Customs. He is a huge fan of concealed carry knives and started down the road with a boot dagger, neck knife and then his Push Talon.

“I think any dagger is challenging due to the symmetrical grinds that are required,” he noted. “You’ve really got to nail each and every one of them or the entire build needs to be scrapped. These push daggers are made with Nichols Slither Armor Core stainless damascus and mother-of-pearl on Westinghouse black canvas Micarta liners.
“Believe it or not, these were my first push daggers,” Matt added. “These were originally made for a customer to match the HawkWing, which is also in this photo. I told him I was planning on doing a pair of matching push daggers, and he asked if we could do the mother of pearl to match his knife. So, I obliged.”

Zack Jonas Totem

A study in starkness, Zack Jonas’ Totem push dagger grabs the eye with its clean lines and depth of damascus. That’s a san mai steel with laddered W’s and faces in a 1,000-layer laminate with pure nickel. Adding to its Spartan charm are its gold handle accents. (SharpByCoop image)
A study in starkness, Zack Jonas’ Totem push dagger grabs the eye with its clean lines and depth of damascus. That’s a san mai steel with laddered W’s and faces in a 1,000-layer laminate with pure nickel. Adding to its Spartan charm are its gold handle accents. (SharpByCoop image)

The Zack Jonas push dagger featured is his Totem model with a blade length of 4 inches and an overall length of 6½ inches. Its gold handle accents complement a san mai steel with laddered W’s and faces in a 1,000-layer laminate with pure nickel.

“The push dagger is one of the few knives that is actually designed to be folded into a tightly closed fist,” the master smith explained. “That means you have to make sure the handle comfortably conforms to the shape of the human hand in that unusual position. A push dagger is not a particularly functional tool outside the very limited frame of hand-to-hand combat; if you don’t have a secure grip when you need it, you’ve got a real problem.

“There are few makers that come to mind as design influences,” Jonas concluded. “[Master smith] J.D. Smith’s early influence on my career is never far from my hand or eye. I also think of Peter Johnsson’s work as I’m designing. He has never done a push dagger that I’m aware of, but I like to try and channel the way he conducts tension through his lines. Peter and [master smith] Kevin Cashen both come to mind when I think of the functionality in any dagger.”

Andrew Meers Rose Of Sharon

A bold mix of materials, Andrew Meers utilizes carbon fiber, stainless steel,  gold and a splintered mosaic damascus to bring-together this 9-inch push dagger. The centerpiece of the knife is its elegant Rose of Sharron engraving with the gold backing. (SharpByCoop image)
A bold mix of materials, Andrew Meers utilizes carbon fiber, stainless steel,  gold and a splintered mosaic damascus to bring-together this 9-inch push dagger. The centerpiece of the knife is its elegant Rose of Sharron engraving with the gold backing. (SharpByCoop image)

Andrew Meers included a push dagger in his ABS master smith set, which was complete with forged trout iron texture engraved with pangolins. “Push daggers have a place in my childhood memory,” he related. “I remember seeing one at a museum and being fascinated. In retrospect, I think having mostly seen conventionally handled pieces in media and collections, the manner in which the hand engages the handle is what is attractive to me.”

Meers’ featured push dagger is his first with a carbon fiber handle and a groove in the blade. Its 7-inch damascus blade is framed in stainless steel, and the engraving depicts the Rose of Sharon with a gold-plated relief background. The entire push dagger is 9 inches long. Andrew produced his first push dagger in 2014 and has made several since. His longest measured between 23 and 24 inches.

Jean Potvin Romanesque

Since push daggers are illegal in Jean Pierre Potvin’s homeland of Canada, he had to come up with a clever trick to get his his Romanesque push dagger past airport security and to a buyer at a show in Las Vegas. His solution, remove the illicit handle and replace it with a toilet plunger handle. (SharpbyCoop image)
Since push daggers are illegal in Jean Pierre Potvin’s homeland of Canada, he had to come up with a clever trick to get his his Romanesque push dagger past airport security and to a buyer at a show in Las Vegas. His solution, remove the illicit handle and replace it with a toilet plunger handle. (SharpbyCoop image)

“This push dagger is Roman in style,” remarked Jean Pierre Potvin. “It came about quite by chance. I rarely design in advance when I create. I prefer to let my imagination run free and follow new ideas that present themselves during the making process. During the making, I saw that it had a somewhat Roman style, and I continued in that direction with this result.”

Potvin’s push dagger measures 8 inches overall with a 4½-inch blade of damascus in 15N20 and 1084 carbon steel. The handle is fashioned from stabilized walnut burl and brass furniture. He had previously made only one push dagger. That was in 2022, and it was much smaller. “I had a buyer at the Nashville knife show,” he remembered, “and I had packed it in my luggage to take there. But when I got to the Montreal airport, it was confiscated by airport security.”

Since push daggers are illegal in Canada, that experience inspired Jean Pierre to remove the actual handle and replace it with a toilet plunger handle the next time he traveled with a push dagger. He made it to Las Vegas that second time and reattached the original handle after arrival. “It’s really funny because it’s the same dagger, but having a cross handle makes it illegal,” he smiled. “Sometimes you have to use tricks to get what you want.”

Somehow, the push dagger and its adventurous history seem to fit right in with Potvin’s novel experience.

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Remembering Hawaiian Knifemaker Keith Derrick Ouye

BLADE Staff
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Remembering Hawaiian Knifemaker Keith Derrick Ouye

Remembering a dedicated craftsman of the Fujisaka lineage known for his tactical precision and collaborative artistry.

Keith Derrick Ouye, award-winning knifemaker of Honolulu, Hawaii, passed away on October 5. He was 80.

A stocky, happy guy well-liked by both knife enthusiasts and his knifemaking peers, Keith primarily made tactical knives, though he also built hunting knives to sell at local gun shows. In addition, he made fancy folders, often with fine engraving by Bruce Shaw, C.J. Cai or Lisa Tomlin. Keith exhibited his work at the BLADE Show and other top knife events over the years. Like many Hawaiian knifemakers, he was a student of BLADE Magazine Cutlery Hall-of-Fame® member Stanley Fujisaka.

Born in South Hilo, Hawaii, Keith lived in Hawaii Kai on the island of Oahu. “I spend most of my day working on my knives,” he wrote in his mini-bio on the Arizona Custom Knives website. “With assistance and guidance from Stan Fujisaka, I started to make fixed blades in early 2004. By the end of 2004, I also started making folders. I began making knives full-time in 2005.”

Keith was a big believer in sole authorship, noting “except for the screws, dowels, standoffs and pivots, I fabricate the rest of the knife myself.”

Remembering Others The Knife Industry Has Lost:

Cool Custom: Jesse Hu’s Thorfinn Daggers

BLADE Staff
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Cool Custom: Jesse Hu’s Thorfinn Daggers

Hu takes the Vinland Saga’s famous daggers from screen to steel.

Anime and knifemaking are seldom mentioned in the same sentence. However, with a pair of striking daggers, an online knifemaking sensation has skillfully forged together that creative gap in cold, hard steel.

Jesse Hu is a multiple Forged in Fire champion and a prolific YouTube creator. When his online fans demanded a rendition of Thorfinn’s daggers from the popular animated Vinland Saga series, the adventuresome smith didn’t back down from the challenge. However, he set stringent goals for how he wanted the fictional blades to materialize.

“I have seen a lot of people make their own versions, but I haven’t seen any that truly captured their energy from the anime,” Hu said. “I felt it was possible for me to make a pair of daggers that fans would feel I directly pulled from the screen.”

The results are a spot-on set of daggers boasting 81/2-inch blades of 80CrV2 steel with carved Ringed Gidgee handles and one with a 1/2-inch-thick brass guard. Hu’s carving emulates the animation’s leather-wrapped look. While there is little actual Viking in the daggers’ overall design, the maker’s choice of wood for the handles did inadvertently bring a touch of the historic accuracy to the fantasy knives.

“One thing I discovered from a friend was that there were a bunch of carved wooden handles on Viking-era blades,” Hu related. “But I only heard about this after I had finished the daggers.”

Hu estimates he put two weeks of work into his rendition of Thorfinn’s daggers. In the end, the project was a labor of love, with Hu compensating himself by keeping the daggers. (Jesse Hu image)
Hu estimates he put two weeks of work into his rendition of Thorfinn’s daggers. In the end, the project was a labor of love, with Hu compensating himself by keeping the daggers. (Jesse Hu image)

The greatest challenge in bringing the two-dimensional blades into the physical world came from the inconsistency of the source material. In the anime series, Thorfinn’s daggers can change from scene to scene, forcing Hu to hit a moving target.

“Some pictures made the handle look rectangular in cross section as opposed to ovular; some made the central fuller look really thin and others quite thick,” he said. “I had to pick and choose from all these images to create something that felt accurate to all of them.”

Studying frames from the series and interpreting how the ink daggers’ ratios translate to steel was a painstaking process. Hu estimates he invested two weeks bringing the anime knives to life. Given the dedicated following of Vinland Saga, he figured the time invested would have paid off—had he not decided to keep them for himself.

“A cool piece doesn’t always mean a smart business decision,” he quipped.

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