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.

Featured Knives – – Knife Collecting – – Tactical Knives – – Survival Knives

A Dazzler For Kaz

A Father, With The Help Of His Uncle, Works To Make A One-Of-A-Kind Knife For His Son After Living The Life Of A Military Kid.

The hardest question for my son Zachary “Kaz” Kazmir to answer is “Where are you from?” His answer usually falls along the lines of, “Home is where the military takes your family.”

Zach’s answer is true for just about any token “military brat.” Military families often move every two to three years—that’s a rate of 10 times more than average civilian families. Living this kind of life for a child requires tremendous resilience, exceptional adaptability, and an uncommonly high maturity level. Zach would repeatedly get settled in a routine, a school, a friend group, and community activities, only to pick up, leave it all behind and start fresh again. 

Oh, and the trials of life do not stop there. He persevered through my frequent deployments, earthquakes, accidents, and even a direct hit by one of the strongest tornadoes ever recorded while he was living in Moore, Oklahoma. Zach’s life led him on a journey spanning two countries, four states, and five schools.

Bobby Kazmir and his son Zach.

I wanted to give the young man something special on the occasion of his 21st birthday. Even with all the places he’s lived and the experiences he’s had, Zach’s fondest memories always gravitate to his time in Okinawa, Japan. The first memories of his life were created there. Okinawa will forever hold a special place in his heart. With that, I set out to have a knife crafted in hopes of capturing and honoring these priceless memories for him.

Uncle Stanley

I could think of no better place to turn for such a task than my uncle, Stanley Buzek. Uncle Stanley is a knifemaker from Caldwell, Texas, and is most certainly the right man for the job. There’s no one I know who puts as much heart into his craft as Uncle Stanley. He guided me through the many options, and I closed in on what would become the most meaningful and elegant 4.5-inch, two-blade Texas trapper I’ve ever seen.

My uncle crafted the frame and liners from raw bars of integral 416 stainless steel. As with each of his knives, he added a personal touch to the spine. This was truly amazing to witness. I’ve seen many of his finished knives over the years, but I hadn’t realized the level of precise craftsmanship he put into the pieces that non-makers like myself often take for granted. Most of us just naturally look to the business end of a blade.

In thinking of the knife for this gift, I aimed to give Zach a glimpse into his resiliency through my eyes. He has been stretched so thin that at times his only choice to keep from breaking was to fold over in the fetal position to regain his strength. He’s been heated, hammered, pressed to the edge of his capabilities, put back in the fire, crushed, bent beyond his limits, beaten down even more, and subjected to unrelenting pressures in different directions.

Nonetheless, he emerged from the fire stronger than ever before, with a character that can only be described as beautiful—just like the banding and mottling of damascus. The beautiful steel forged by Bill Poor couldn’t be more fitting for this knife. Bill transformed raw 1084 carbon and 15N20 nickel-alloy steels into an extra-fine River of Fire pattern with elaborate feathering that perfectly captures how I view Zach’s coming-of-age: indicative of many intense moments, but not scarred. Instead, radiating with a unique, luxurious magnificence that exemplifies resilience.

Making The Knife Handle

The next essential element on my mind was the scale material. (I called it the “side of the knife” but you know how knifemakers are about educating the ignorant.) The scales had to be more than just the perfect material, they had to be uniquely sourced. I wanted my son to have a literal piece of his childhood that he could hold in his hands whenever he wanted. 

Scanning the beach for seashells while barefoot along the shoreline of Okinawa’s Devils Cove is no doubt among Zach’s favorite island memories.

I reached out to a military friend stationed in Okinawa to acquire a piece of one of the famed, colossal banyan trees from the island. With travel restrictions, import/export regulations on agricultural items, and COVID-related shipping delays, it proved much more difficult than we expected. However, my contact was able to come through! After nearly a year, a heavily worn, 5-by-10-inch piece of banyan tree finally arrived in the mail.

Uncle Stanley was reluctant to use banyan. He cautioned me not to get my hopes up because he knew how challenging it can be to properly stabilize such a soft wood. In addition, the sample was very weathered, extra-soft, and had several deep cracks inflicted in transit during shipping. In other words, there wasn’t a lot of room for error! 

Uncle Stanley sent the wood to the very capable Terry Dunn of TNT Enterprises, and I was truly blown away by what he was able to do. Dunn not only stabilized the wood, he preserved its beautifully subtle grains and the small, intricate pitch pocket. The latter is a cavity in the wood where the tree suffered some sort of damage over its life, or a small knot of sorts if you will.

Stanley assembled the sleek trapper, affixed the scales, and presented me with a truly remarkable knife. Then he took it from my hands and said, “Now it’s time to go get it ‘scratched up.’”

Engraving The Knife

A slight fear came over me. I worried that an engraver could potentially damage this work of art. However, the worry left me as quick as it came when I learned the engraver was Alice B. Carter. I’ve seen her amazing work in the past. I knew she could add another layer of beauty to the piece.

To my surprise, Alice asked so much more than, “What would you like me to engrave?” She had an authentic interest in the story of the knife and its eventual recipient. I think she asked me more about Zach than she did about art that day. I shared with her the things Zach tends to reminisce about from his time in Okinawa, and we honed in on a few specifics.

One of the first memories of his life is enjoying the annual Cherry Blossom Festival in Okinawa’s capital city of Naha. The festival draws crowds of thousands each January to see the city streets completely encased in the vibrant blooms. Zach also speaks of how massive he remembers the banyan trees being there. If you’ve never seen a 200-year-old banyan, the behemoths appear to be as old as time and so wide they seem to fill the sky with a majestic, towering presence as if from a fantasy movie. 

Alice’s smile grew wider and wider as we continued to talk through a few other details. She drew inspiration from our chat and created an absolute masterpiece. Engraving for more than 40 hours and inlaying more than six feet of 24k-gold wire, she created so much more than a scene or picture. Her art marvelously captured the emotions connected to the memories.

Reaching from corner to corner on the upper bolster of the facing side shines the island of Okinawa in pure, radiant gold. The shading effect seems to literally draw the island’s shape out from the knife. Carefully inlaid in the exact location of Kadena Air Base where Zach lived on the island, a one-millimeter copper marker memorializes his time there. 

The lower bolsters hold a personal message from father to son: Ichi-go ichi-e. Emblazoned in bold Japanese Kanji, it is an idiom roughly translating to “for this time only.” Reaching from corner to corner on one side of the upper bolster shines the island of Okinawa engraved by Alice Carter in 24k gold. The knife’s oversized shield brilliantly gleams Zach’s nickname of “KAZ” in Japanese-styled English letters. (SharpByCoop image)

On the opposite side in exquisite detail is an ancient, powerful banyan tree spanning from edge to edge. In a beautiful complement to the gold inlay, the banyan’s leaves are adorned with Alice’s self-alloyed green gold. Zach can view the upper bolsters in remembrance of the land he once knew.

As is customary in the military, a servicemember’s last name becomes his or her first name. It’s the military way. Kazmir was shortened to “Kaz” almost immediately, and that nickname stuck for the entire two decades I served. As Zach approached adulthood, he began to go by this moniker as well. The knife’s oversized shield brilliantly gleams “KAZ” in Japanese-styled English letters—an embodiment of how I’ve passed on my name to my boy.

Finally, the lower bolsters hold a personal message from father to son: Ichi-go ichi-e. Emblazoned in bold Japanese Kanji, the message is an idiom roughly translating to “for this time only.” It means that Zach’s experience in Okinawa was truly a once-in-a-lifetime episode that can never be duplicated, and he should treasure it forever.

Alice brought all the components together by incorporating gorgeous cherry blossoms engraved with intricate detail resulting in what I see as the perfect gift. Zach received it as a Christmas present and shed some heavy tears as I explained each element. He and I are both still amazed at how everyone came together to help me make this one-of-a-kind knife happen.

Uncle Stanley once told me that nearly every knifemaker is an expert at something, but no knifemaker is an expert at everything. He described knifemaking as a network of experts who bring their talents together to make the impossible possible. In the military, we have a term for this—it’s called synergy. With this beautiful piece, I’m convinced the knifemaking community is synergy at its finest.

For more information about the knife, contact Stanley Buzek, Dept. BL8, P.O. Box 621, Caldwell, TX 77836 346-412-2532 [email protected], s.buzekknives.com.

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BLADE Show West Custom Knife Awards

Awards Were Given Out In Nine Different Custom Knife Categories Including Best In Show At BLADE Show West In Salt Lake City.

Dozens of makers entered knives in competition across eight different custom knife categories. The skill on display was tremendous, and numerous knives wowed the judges. However, these were the blades that stood out from the crowd and took home the awards. All images are SharpByCoop Images.

Best In Show/Best Kitchen Knife: Trevor Morgan

Best Hunting Knife: Shayne Carter

Best Damascus Custom: Shane Taylor

Best Custom Slip Joint: Evan S. Nicolaides

Best Custom Tactical: Michael Jarvis

Best Custom Locking Folder: Tim Robertson

Best Custom Bowie: Shayne Carter

Best Custom Chopper: Mardi Meshejian

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Dads And Daughters: Passing The Art Of Knifemaking Down

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The Older Generation Is Teaching The Next Crop Of Makers The Ropes Of How To Turn Steel Into Knives And Knives Into Memories.

Though it isn’t rare for kids to follow in the footsteps of their parents when it comes to choosing a career, the path to becoming a well-known custom knifemaker may just involve a bit more dedication than most other vocations.

For American Bladesmith Society (ABS) master smith Josh Fisher and Wolfgang Loerchner, the adventure has been quite rewarding as their respective daughters, Karis and Elizabeth, have become quite accomplished in their own right. 

Josh And Karis Fisher

The 2021 Texarkana Hammer-In was a memorable one for the Fishers, with Karis earning her ABS journeyman smith (JS) stamp, Josh his ABS master smith (MS) stamp, and each taking home the annual award for the best knife submitted by a JS and MS.

“When I was younger, I would always sit out in the shop watching my dad make knives,” Karis remembered. “Over time, I slowly started messing around sanding on pieces of metal, thinking I was making a knife. This eventually led to my interest. My first knife was a small full-tang hunter with a pink handle that my dad helped me make.”

Josh, no doubt, was ready and willing to help his daughter hone her skills when the time came. “Karis has always been pretty good at grinding blades,” he smiled, “but she struggled with guard fit up for a while and finally got that figured out.”

Of course, there were challenges and an obstacle or two along the way as Karis gained knowledge in the custom knifemaking world. She spent time at the forge, hammering away in preparation for ABS recognition, but that got placed on hold for a while.

“Yes. Definitely, I had a few setbacks,” she reflected. “I first attempted the ABS journeyman smith test in 2019 and failed. I then tried to retest the next year, but due to [the pandemic] it was canceled. In 2021, at the Texarkana Hammer-In, I finally got to retest and passed. Looking back, I think it worked out for the best because I was able to come back and win the Keeslar Award.”

The Joe Keesler Award is an annual honor for the best knife submitted by a successful journeyman smith applicant. If nothing else, the award validated the hours that both Josh and Karis had dedicated to her custom knife and bladesmith upbringing. And making the year extra special, Josh received his ABS master smith designation at the Texarkana Hammer-In, and later the B.R. Hughes Award for the best knife submitted by a successful master smith applicant. It, too, is an annual honor.

Josh added that sheer space and equipment limitations have impacted the progress of the Fishers’ work from time to time.

 “One of the main obstacles is working around each other in the shop,” he said. “We currently only have one grinder, so we sometimes have to wait for the other to finish before getting to work. Another grinder is definitely one of the next tools we are going to have to get.”

Bog oak comprises the handle of a Karis Fisher fixed blade with a recurve damascus blade.

Despite a little inconvenience, Karis has come a long way in a relatively short period of time. Family and friends are impressed. 

“All my relatives have always thought that it was cool,” that I made knives, she observed, “but my friends have always thought it was a little strange, especially the fact that my Instagram account has no pictures of me, just my knives.”

Her mom, Kim, is a big fan. “My wife loves to go to knife shows,” Josh related, “so she has always been supportive and happy about Karis and her work in knives.”

While Karis isn’t sure of an exact moment when she knew she wanted to make knives, the idea was never far from her mind. “I think I’ve always kind of known that it was something that I wanted to do,” she noted. “I enjoy making all types of knives, but small hunters are probably my favorite right now. I recently made my first slip joint, and I think they could easily become my new favorite.

“Probably my favorite part of knifemaking is seeing the finished product. But, if I had to choose an actual step, it would be all of the small embellishments and final finishing of the knives. If I had to pick a least favorite part, it would be hand sanding the blades!”

Wolfgang And Elizabeth Loerchner

Wolfgang Loerchner (left) and Elizabeth (right) had to share space in Wolfe’s crowded shop in the early days—at one point including long hours seven days a week for about a year—but it has all paid off. In the middle is Wolfe’s granddaughter by his eldest son.

The year 1982 was momentous for Wolfgang Loerchner. He made his first knife, and topping that achievement, his daughter, Elizabeth, was born. 

“It almost seems as if this path was destined for her,” he smiled. “Knives were a part of her life from the very beginning in various ways—observing the stages of the creation of a knife, the many shows, photos, and articles of the knife shows as seen in various magazines, observing friends visiting, and the many conversations that surrounded all aspects of knives. In some way, shape, or form, knives have always been a part of Elizabeth’s life.”

Elizabeth made an early step into knifemaking and then regrouped. Her second foray has been hugely successful.

“Having always had a strong interest in the arts, knifemaking was something I considered at one point when trying to decide my future,” she commented. “I made one attempt at knifemaking in 2003-2004. However, it quickly became apparent that the timing was not correct. It was not until several years later, after visiting the Milano Show in 2009, that I became truly inspired.”

Elizabeth and Wolfgang were sitting together on their return trip from the Milano Show, and she presented him with the idea of teaching her again. Of course, he was more than happy to get started, and Elizabeth began working on a knife design immediately. In January 2010, she sat down with her father once more—this time in his shop—and custom knifemaking quickly became a huge part of her life.

“I’ve had a couple of personal situations that did set me back,” she related, “but they have not kept me down. All around, there has been full support of my decision. Everyone has been happy to see me working in the arts and also to be carrying on what my father has been doing.”

Elizabeth’s mother, Dianne, shared a positive perspective. “I was glad for her, that she was able to use her artistic abilities to create knives. During her high school education, Elizabeth was always happiest when she was in the midst of creating an art project. In the few years directly after high school, she was thinking about steel and what she could do artistically with steel, which seemed a logical first step to me. 

“Elizabeth has an artistic flair that is unique to her, different from her father’s, and allows her to create pieces that carry more of a whimsical note to her knives. This is reflective of her deep creative ability. When she asked her father to teach her, I was a little hesitant since she had been living away from home for several years. While there were several tense moments, overall it was a good experience for both of them.”

Elizabeth’s knives have been recognized by aficionados worldwide at such exclusive venues as the Arts In Metal Show in Stresa, Italy, including this piece from the 2014 event. In fact, both she and her father have been regular exhibitors at the elite Italian show. (Francesco Pachi image)

The commitment of time and energy made for a few challenges in the learning process, but the entire experience has been worth the investment for Wolfgang and Elizabeth. Each has a distinctive design and artistic expression, coexisting, learning, and producing outstanding objects of art.

“One of the greatest obstacles we probably had to face was learning to work so closely side by side for so many long hours,” Wolfgang recalled. “There were other small obstacles. Working together in this way involved learning a whole new form of communication. We would often be saying the same thing but speaking it in a different language. Many mistakes were made as a result, but in due time we found our way to overcome this obstacle and work through things more smoothly and efficiently.”

Elizabeth recognizes the fact that she has learned to accept constructive criticism and teaching moments from her father. Wolfgang, on the other hand, points to a new method of communication developed as they worked together. Still, Elizabeth is adjusting.

“The most difficult part has been living in the path or shadow of my father,” she noted, “with the sense of needing to live up to the expectations of others. Creating my designs, it only seems to come naturally that my style is so similar to his. There are many reasons for this, and I constantly strive to find that fingerprint of my own.”

Elizabeth has always been an accomplished artist, drawing and painting with passion. Holding a file seems to come almost as naturally as working with a paintbrush or pencil. So, as her hand-eye coordination came together almost effortlessly, working in steel and making lines flow in knives was virtually second nature.

Fixed blades and integrals are the favorite types of knives for Elizabeth, and she appreciates their aesthetic qualities. 

“There is something about the power and strength of them,” she reasoned, “and what seems to be a limitless canvas. There is something pleasurable about working with folders and how the knife changes, whether open or closed. When working with daggers, fixed blades, and integrals, the limitations of working around the mechanical parts have been removed, and I find this gives more freedom to my designs.

“The most pleasurable part of knifemaking,” she added, “is the filework. Watching the steel slowly come to life, seeing the design come out of it as if it always lived there, is highly rewarding. The final finishing of a knife can be the most frustrating part. This is when any possible flaws start coming to light. Since I am my own worst critic, it can turn into a never-ending process of doing multiple things over and over again.”

Nonetheless, the Loerchners know they were destined to work together, one to learn from the other. In turn, each helps the other reach new heights of artistic expression.

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Keepin’ Those Day Jobs: Knifemaking Side Hustle

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For Many Makers, Knifemaking Isn’t A Full-Time Job. Here’s How Some Fill Their Days When They Aren’t Sharpening Steel.

One of the more memorable henchmen of the James Bond series is the stout little fellow Odd Job, played in Goldfinger by Harold Sakata, and a popular character in the Nintendo series of Bond video games. He has a hat with a razor-sharp brim that decapitates a marble statue in the movie and guarantees an instant kill in the game.

He’s a master of body paint, a capable golf caddy, and can crush a golf ball with his bare hands. He’s a chauffeur capable of skilled pursuit and evasion in the inevitable Bond car chases. In the end, this man of many talents meets an untimely death by electrocution in the vault at Fort Knox.

Many who make knives choose not to make it a full-time career but a mega-hobby or part-time job instead. There are many of us, both known and unknown, who work “regular” and “boring” jobs to fund our knife passion. Though I write and make knives, I’m a behavior analyst in my day job. My brother Travis is a knifemaker and accountant—boring! I bet you’ll be surprised at some of the unusual talents that support some knifemakers in the daytime so they can pursue their blade craft on nights and weekends.

Michael Quesenberry

ABS master smith Michael Quesenberry is well known for his intricate integrals, precise damascus and meticulous attention to every detail. He’s a professional engineer in his day job but not one of the calculator-and-pocket-protector types; he drives a train. He’s been a full-time locomotive engineer for the past 27 years with the Union Pacific Railroad. Meanwhile, whenever knifemaking starts coming with medical, dental and 401(k), he promises to switch careers.

Ricky Bob Menefee

Ricky Bob Menefee describes himself as a “dog catcher.” For the past 24 years he’s been a full-time trapper for the U.S. Department of Agriculture. Sometimes his job is predator control, setting foot traps, snares or poison for calf-eating coyotes or lamb-snatching bobcats. Other times he hunts crop-destroying wild hogs via a helicopter or uses dynamite to blast out beaver dams.

“I’ve been lucky my whole life,” Ricky says. “The only thing I’ve ever done was hunt, fish and make knives. Knives have allowed me not to have to find a ‘real job’ because my federal job has good benefits to go along with bad pay.” Ricky specializes in fixed blades and slip joints well suited to outdoor tasks, and his tiny tapered tangs are legendary.

Jason Floyd

Jason Floyd describes himself as a “professional grass grower” after 20 years in the golf course business. The damascus and cocobolo knife is one he made in an integral construction. The Mickey Mouse golf towel is a memento from his grandfather.

After 20 years in the golf course business, Jason Floyd says he’s a “professional grass grower.” He started as a turf expert and ended up as a golf course superintendent. Now he works as a forge and blacksmithing tool fabricator for Well Shod Farrier Supply and supplements his income with knifemaking. He says knifemaking is better than watching the grass grow. Jason specializes in forged and damascus fixed blades.

Kelly Kring

I learned a new word from Kelly Kring, who used to work as a “diener” or autopsy technician. He was responsible for moving and cleaning bodies, assisting the pathologist with autopsies and collecting evidence. After that he became an occupational therapy technician in a hospital burn unit. Now he describes himself as “a full-time blacksmith who happens to teach smithing classes at a local college.” He says, “I’ve made knives for many, many people, but don’t call myself a knifemaker.” Kelly is well known in blacksmith circles for being an excellent hands-on instructor.

John Thunert

All the bugs and creepy-crawly varmints better watch out for John Thunert, a self-described “killer for hire.” John works full time as an exterminator. When the pandemic shut down his business, knifemaking took up the slack. John is a Forged in Fire runner-up from season six, episode 18, and has been making knives for four years. “I’ve gotten bored with the other hobbies I’ve been proficient in. Knifemaking and the challenges it presents should see me through another 20 years,” he observes, “and I still won’t accomplish all the things I want to do.” John prefers making fixed blades and forges his own damascus and san-mai.

Josh Howard

Josh Howard makes robots for the Polaris factory and also enjoys his Chambersburg power hammer.

Many knifemakers know how to weld. Josh Howard of Deerlick Ridge Forge can beat that—he teaches robots how to weld. In the daytime, he works for Polaris Industries in the factory where they manufacture the four-wheeled side-by-side Ranger robots and the three-wheeled go-fast Slingshots. 

He writes the programs that drive the automated welding robots, placing precise welds at critical structural points on the vehicles as they are assembled. Josh is a Forged in Fire competitor from season six and specializes in damascus kitchen and hunting knives. He says “Deerlick” is the name of the creek down the hill from his shop, and that nobody actually licks the deer.

Jason Wilder

The apostle Paul was a tent maker and did enough of that work over the years to support his ministry. Jason Wilder is a Church of Christ minister and supplements his work with knifemaking. After all, the Bible does say “the Word of God is sharper than a two-edged sword.” Jason admits that he may occasionally carry a sidearm and a knife in the pulpit and on pastoral hospital visits. 

“Nobody goes into church work or knifemaking to get rich, but my family gets by on the combination of the two,” he notes. “My ministry schedule allows me to make knives, and my knifemaking supports my vocation as a minister.” Jason makes Sunday-go-to-meeting-quality fixed blades, both forged and stock removal.

Terry Vandeventer

In addition to forging impressive fixed blades, ABS master smith Terry Vandeventer is an expert snake handler. Terry has enjoyed a long career as a professional herpetologist, an expert in reptiles and amphibians. He started out with snakes as a zookeeper, and eventually built a business breeding rare and unusual snakes for zoos. 

While he says he’s past his prime in the snake business, he still has “only” about 75 snakes in his current lab. Terry continues to make knives as a source of stress relief, and says “When the knife business gets stressful, it doesn’t serve its purpose for me.” I don’t know about you, but I’d find the North American pit viper collection a bit more stressful than knifemaking.

Bryan Borton

Bryan Borton has spent nearly 30 years in the concrete-sculpture-casting business with his wife Kristy. Bryan crafted this fileworked hunter with stainless bolsters laser engraved by Tyler Poor.

Where do birdbaths come from, anyway? Besides, were birds dirty before people started making birdbaths? Do baby birds prefer baths and older birds prefer showers? My friend Bryan Borton has spent nearly 30 years in the concrete-sculpture-casting business with his wife Kristy. He claims to have made thousands of concrete birdbaths, and his most unusual casting jobs include giant mushrooms, his brother-in-law’s headstone, and some great big soda bottle replicas. 

He began making knives seven years ago, learning first from me and then from Travis Payne and some members of the Texas Knifemakers’ Guild. His knives are popular among the rodeo and ranching crowd, as you might suspect given his West Texas location.

Robert George

Robert George is an electrical engineer. Boring, right? Not at all. Robert was the chief architect at AMD (Advanced Micro Devices) for the computer chips used in the Playstation 4, PS4 Pro and PS5 video games. 

If you’re a gamer, you’ve probably used his work and didn’t know it. Robert describes himself as a “100 percent bladesmith” because he enjoys the artistic expression of forging close to the final shape. He studied with ABS master smiths Jim Crowell, Timothy Potier and J.R. Cook at the Bill Moran School of Bladesmithing in 2010 and has been passionate about knives ever since.

The List Goes On And On

There are some lists that will always be incomplete, and this is certainly one destined for deficiency. I didn’t have time or space to include BLADE Magazine Cutlery Hall-Of-Fame® member James Batson the rocket scientist, Les Adams the bomb squad technician, Jeremy Spake, who builds armatures for stop-motion animation films, or Grace Horne, who builds custom lingerie. I

 also left out a bunch of knifemakers with exotic hobbies like ABS master smith Jordan LaMothe, who performs in musicals, Ryan Breuer, who does ballroom dancing contests, and I’m sure I left out plenty of great stories about people I haven’t met yet.

You and I may have different vocations from each other, and surely don’t have the same jobs as some of these knifemakers. Even so, one thing that joins us all together is our appreciation for knives. Handmade or user grade, for display or cosplay, for vegetable cutting or whitetail gutting, our love of knives brings all of us together in our occupational diversity.

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Making A Knife With A Legend Bob Terzuola

The Author Got To Spend A Weekend Making A Custom Knife With Legendary Maker Bob Terzuola

Over 30 years ago when I was just getting into the knife collecting hobby, I was at a gun shop on Long Island. I noticed the knife in the salesperson’s pocket and asked if I could see it. It was a custom Bob Terzuola. 

I had my own Spyderco Terzuola factory/custom reproduction that recently had been introduced and I was amazed to see and handle a custom Terzuola for the first time. I thought to myself that someday I would own a custom Terzuola. Little did I know that one day I’d have a chance to make my own custom knife with Bob as well.

In the course of my “collecting career” I managed to get one Terzuola—to say the least.  Now I have around 75 Terzuola knives! During this journey, I’ve met Bob many times and we’ve become friends. He’s a truly remarkable person who’s been making knives for over 40 years. More than just a knifemaker, he is an artisan, inventor, and craftsman, too. In addition, he has plenty of interesting stories to tell.

This past fall, Bob and his wife, Susan, were in Chicago and we met for dinner. It was around my 50th birthday (which, coincidentally, I share with Susan). As a gift, Bob invited me to come to his shop near San Diego to make my own knife.

So in March I flew to San Diego to spend a few days with Bob at his storied “Knife Camp.” I was a bit nervous. I don’t really have any knifemaking or even machinery type experience. My family came along with me—my daughter loves Bob’s dogs, while my wife enjoyed the local botanical gardens with Susan, who is an artist and a master gardener.

Who Is Bob Terzuola?

Bob’s knifemaking journey began in Central America. In the late 1960s, he served in the Peace Corps in Panama. After completing his service, Bob settled in Guatemala, where he managed a jade company. It was there, in the late 1970s, when Bob began to first make knives, mostly for military operatives in Central America. In 1984 he returned to the USA and set up shop in Santa Fe, where things really took off. 

Bob is often referred to as the “father of the tactical folder” and is best known for his ATCF (Advanced Technology Combat Folder) model, which was released in 1985. Wanting to create a discrete yet robust, functional, and easily deployable knife, Bob was one of the first custom knifemakers to use titanium, pocket clips, and G-10. 

He was among the first makers to use a thumb disc and have parts laser cut. Bob is also credited with being the first custom maker to do a knife collaboration with Spyderco. Made in 1989, the knife was the Spyderco C15, which held patents for being the first U.S.-made factory knife using premium steel and G-10, along with a linerlock.

Bob Terzuola’s Shop

Bob shows the author how to grind.

When you first walk into Bob’s shop, you’re immediately struck by how neat and organized it is. As far as equipment, he has all that’s required with over a dozen machines including a band saw, milling machine, grinders, drill presses, and blasting cabinets. 

More than the equipment, though, Bob’s shop is like a history of his knifemaking. The shop is dotted with mementos of his career, gifts from customers, letters of praise, awards, and trinkets from over the years. There’s also a collection of police patches from all over the world, along with hats and photos. On one bench he even has an artillery shell. Of course, the C15 Spyderco knife patent is on display as well. 

Knifemaking With Bob

Using the lathe, Bob helps the author trim the pivot barrel to the proper length.

Time to make a knife! We decided to go with a 3-inch tanto folder, which is one of my favorite overall configurations. Bob suggested basing it on his Mini Athena model. He already had two handle liners cut out that we could use. I had to do the rest.

He explained the basics of operating the machines and got me to work right away. Within 45 minutes of pulling into his driveway, I was using a bandsaw to cut a blade profile drawn on a sheet of MagnaCut steel. Then I was drilling the pivot and screw holes in liners, countersinking holes, and smoothing out edges.

Things got quite serious when Bob had me “practice” taking the blades out of the heat treat oven. It’s pretty crucial to not drop the blades, which are heated to 1900° each when removed from the oven. Oh, and you read right, I did say “blades” as Bob had me cut two in case I screwed one up at some point. Fortunately I didn’t drop the blades after the heat treat, so that was a relief.

Next, I picked out my scale material. I like Micarta® so green canvas Micarta was an easy choice for me. Bob gave me a sheet of the material and off to the bandsaw I went. Same for the backspacer, for which I used some yellow/white Micarta for a bit of contrast.

The next day a lot of time was spent cutting the lockbar—Bob set up the milling machine for me—smoothing out the scales, adjusting stop pin placement, and putting the handles together many times to make sure everything fit just right. 

Of course, all the work was made a bit easier and more efficient by using the tools that Bob has made, often even invented, over the years. His shop is filled with a plethora of tools, devices, holders, clamps, and more, many of which he’s designed and made himself to make his knifemaking process more reliable and efficient.

Next came the grinding, probably what many think of as the hardest and scariest part of making a knife. One of the first things Bob said to me when I arrived at Knife Camp was, “We can always take more away but we can’t put things back.” I think that nowhere is this truer in the knifemaking process than in grinding a blade. If you make a big mistake here, there’s no fixing it. Obviously, there is a practiced art to this. I seemed to do OK on the grinding part—until I wasn’t.

Overall, I ground the blade well but got sloppy on one of my final passes. I started a bit too soon and ground some of the area near the detent hole. When we put the knife together, it was pretty clear that the mistake had implications. Basically, there was no detent. It was pretty disappointing, but then we remembered the second blade I cut in the beginning. Clearly, Bob had been thinking ahead.

Finishing My Blade

The finished knife is based on one of Bob’s Mini Athena models sporting a 3-inch tanto blade of MagnaCut stainless steel and a green canvas Micarta® handle with pocket clip.

On day three I got to work grinding the second blade and managed to not repeat my mistake of the day previous. Then I sandblasted the blade. After that, I began the process of putting the knife together, taking it apart, tweaking it a bit, putting it back together, all over and over again until it worked just right. Finally, the action, lockup, and centering were good. Bob sharpened the knife for me and it was done.

I don’t know that I’ll ever be a knifemaker but I made a knife, and I love it!

Over the years, I’ve gained a lot of knowledge about knives but to actually make one was something else entirely. The amount of planning and work, especially detail work, that goes into a handmade knife is truly remarkable. Being guided by and watching a master like Bob made my experience even more remarkable. He knows what works well functionally and artistically. He thinks several steps ahead and takes the time with each detail. That’s why his knives are highly desirable.

Thank you again Bob—and Susan—for your hospitality and for making this opportunity happen.

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Shop Dump: Tools The Pros Use

Renowned Makers Across The World Talk About The Tools They Use To Craft Their Metal Creations.

A good craftsman needs good tools. Without a well-stocked shop, knifemakers are held back from creating to the best of their abilities. This trio of makers from around the globe talk about what they use and how it affects their knifemaking.

Jim Crowell

Look close and you can see the faint hamon on this tactical model by Jim Crowell

American Bladesmith Society master smith Jim Crowell has been making knives for over 40 years. A member of the ABS Hall of Fame, he is known for his masterfully hand-forged blades. His Mountain View, Arkansas, shop is well stocked, and he leads off with the Wilmont TAG and Beaumont KMG belt grinders.

“Wow!” he said of the Wilmont. “You talk about smooth running and great and easy tracking, with a swing-out work rest it doesn’t get any better. I really like the work rest, as you just swing it out and lock it—no wrenches or Allen wrenches, adding or removing parts. Worth every penny and then some.”

He continued with praise for the Beaumont KMG. 

“I have used many of these in different schools and have had three myself, to include the one I am using now. These are great grinders and the broad range of excellent attachments makes them top contenders in my book. Both have 1.5-inch tool arms, which means you can switch tooling between the two—a good idea, I think. The small wheel attachments for both are great, and the Beaumont rotary platen is something special.”

Broaches and file guides by machinist/ABS master smith John Perry are next.

“When John designs and makes a tool for knifemaking, there is no compromise, nor anything you don’t need,” Crowell commented. “He knows what the tool needs to do and makes sure it performs in an exemplary manner. There is no reason one’s tools should not be pleasing to the eye. Just hold the gingerbread, please!”

Jim credits the broaches for definitively solving the age-old problem of fitting a square peg—or really a rectangular hole—into a round hole. He calls them indispensable in the shop and they are available in numerous widths. The filing guide eliminates concerns with getting the guard to fit flush to the shoulders of the ricasso.

“Oh, the stories I’ve heard,” Jim smiled. “John’s shoulder fixtures are precise and have several other uses besides filing the shoulder on the tang, but that’s how I use mine the most.”

Crowell tipped his hand a bit in identifying the “Widget” as one of his favorite tools. “This is a handy little thing I added to my slack belt assembly on the Beaumont KNG grinder,” he remarked. “It fits in such a manner as I can run the belt underneath it and use the slack belt feature. You can also run the belt over the top and have a radius that, if properly used, will make minor adjustments to the plunge lines, as well as the choil area under the ricasso. An added benefit is that the sanding lines are lateral now and alleviate trying to sand longitudinally in the radius of the plunge line that was created vertically. Love it!”

The maker summed up his preferences for each of his top tools by identifying their best characteristic. “Realistic design by folks who are intimate with making knives,” he reasoned. “My tools and equipment are not fashion statements. They are not necessarily ‘pretty.’ They were made to do a job and do that job well. There is a subtle beauty in that.”

Jens Anso

]Jens Anso is probably best known for his folders, including this framelock flipper.

Danish custom knifemaker Jens Anso zeroes in on a combination of purchased and self-made shop tools that give him the edge in a full day’s work. He describes his shop as sometimes cluttered, though that’s often a hallmark of a busy and productive craftsman.

The first tool he cites is his horizontal grinder he built about 20 years ago. 

“At that point in time I was used to building grinders and put this one together from parts I had lying around, including a two-speed motor with about 2.2 horsepower, so it will not slow down regardless of what I throw at it. This grinder was fundamental in creating the career I have,” he noted. “Even though I now have new, fancy machines, this one just performs really well. I finished more than a thousand folders using this grinder, especially the frames. It uses a Hardcore small wheel attachment and is super fast to change wheels and belts. It has a small platen that goes on and off really fast, too. This is what all my handles with ANSO texture were ground on!”

The purchased tool side of Anso’s shop is occupied by, among other implements, a Hardcore Maximizer.

“It’s kind of the industrial version of the grinder I described above, though this can do a lot more,” he remarked. “Lots of wheels and platens. It’s slower to change belts and wheels on, but once done will perform! Between this and my other two conventional Hardcore grinders, I am pretty much set. I used to build all my grinders because good commercial grinders for knifemaking are not available in Denmark, and it used to be difficult to import them from the U.S. But I have imported two of these Maximizers and two conventional grinders since then because I prefer making knives rather than making machines.”

A lengthy search also produced the ideal drill presses for Anso’s knifemaking. Though it took a while, they fill the bill to his exacting standards. 

“I had been on the hunt for a great drill press for ages and finally found these vintage Danish-made CLOU machines,” he recalled. “They are heavy duty but precise, have excellent depth stop and two-speed motors, as well as pulleys for changing speeds. This is a fantastic machine for knifemaking. I have had as many as eight of these at the same time but am down to three in active use. With CNC making its entrance into my shop, I still need a few good drill presses but I don’t need eight.”

Lucas Burnley

Asian-style folders with crisply ground blades are a Lucas Burnley specialty. (Eric Eggly/PointSeven knife image)

Lucas Burnley takes a philosophical approach to the development and use of functional implements.

“Like any skill, time is one of the most valuable assets you have,” he observed. “However, buying or building the right tools and equipment will go a long way in speeding your improvement. My tool purchases usually come down to application or interest. The tools I list are considered necessary at a base level and would be able to work well in almost any shop regardless of what type of knife is being made.”

He points to his burly Bader B3 2×72 variable-speed belt grinder as a key player in the day-to-day function of his shop. 

“When someone asks what piece of machinery they should buy first, this is usually my answer. For me, the grinder is the single most important tool in a basic knifemaking shop. With this machine, you can profile blanks, grind blades, shape handles, and about 100 other small steps that make it worth its weight in gold. Buying a quality machine is going to pay off more than you can imagine in the long run.”

Lucas recently added a TW-90 grinder from Wuertz Machine Works and advises that if a maker’s budget allows for it, the TW-90 is a fantastic addition that allows even more complementary functionality to the 2×72 platform. Also, he noted, “If you’re on a limited budget the KMG 1 from Beaumont Machine is a great option. You can skip the variable-speed drive and use the step pulleys and add the VFD [variable frequency drive] down the road.”

A 15-inch belt-top drill press is another valuable component of Burnley’s shop. “One thing the belt grinder can’t do is drill holes,” he laughed. “While you can use a hand drill, a bench-top drill gives you a lot of capacity for short money. Adding a keyless chuck will increase your speed with tool changes. I’ve had a number of these machines over the years, and there are a number of good options on the market. I currently have a model from WEN but will be replacing it with a comparable model from Jet Tools shortly. Quality here matters but much less so than with the grinder. These are not meant to be precision machines, but for 90 percent of the tasks you give them they will be just fine. When I first started building folders, I didn’t have a milling machine and was able to use my drill press to cut the lock relief, lock slot and face on a number of knives with a little creative problem solving.”

A metal cutting band saw and CAD (computer aided design) capability round out the top pieces of equipment for Lucas. The band saw delivers greater speed and efficiency. He has a 14-inch Delta wood/metal band saw made in 1951 that his dad found at a yard sale 17 years ago. 

“The only reason I have it in third place is that your belt grinder will allow you to profile both blades and handle parts if you start with a narrow bar stock,” he related. “With a band saw you will be able to buy larger sheets of material, nest your parts more efficiently, and ultimately use less abrasives, saving time and money through every step.”

Taking time to learn CAD can be a game changer. “One of the best pieces of advice I could give any maker is to learn CAD,” Lucas noted. “Even if you don’t have the money to buy tools or a shop to work in, if you have a computer you can start building a skill set that will help you for years to come. Fusion360 offers free software for hobbyists, and there is an endless number of tutorials available online.”

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Knifemakers And Their Tools

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Knifemakers From Around The World Share What Equipment They Can’t Live Without And How It Helps In Creating Their Knives.

There are high-quality knifemakers on every continent. We chatted with some of the world’s best makers about what equipment and tools are must-haves for them in their shop. 

Bertie Rietveld

Bertie’s Legacy Roman pugio in Dragonskin damascus with a Stanhope lens just below the guard and lapis lazuli cylinders with titanium spacers in-between is spectacular even by his high standards. Overall length: 16 inches. (SharpByCoop image)

One of the world’s leading makers of art knives, South Africa’s Bertie Rietveld is known for magnificent custom daggers and fixed blades, many in his Dragonskin damascus and with a Stanhope lens at the ricasso, a peek into which reveals whatever image Bertie likes to put there—usually the Stanhope logo.

Among his knifemaking equipment that proves invaluable to building his award-winning knives are his Rosa Italian precision drill presses. 

“I have three of them,” he wrote, “each one set up with a different-diameter drill bit so I don’t have to change bits. The speeds are set to match the ideal speed of each drill bit in the chuck of each machine. They are super accurate and an absolute pleasure to use when drilling small holes. Each one has a light that automatically comes on when you start the drill. They’re probably 30 years old but I have rebuilt them to their former glory.”

Next on Bertie’s list of top knifemaking machines is his Schaublin 102 plain lathe. 

“It was manufactured in 1961, which makes it a year older than me!” he grinned. “I have a full set of collets and chucks for it and use it a lot to turn small pins and pivots for my folders. It’s one of those machines built in the golden area of mechanical excellence: the 1960s. I love working on it because it’s very accurate and just a solid, well-built machine.”

Third among his most valuable knifemaking machines is his Cutlermatic belt grinder, which he built about 20 years ago when he ran Batavia Engineering. 

“We built some 300 of these grinders for knifemakers at the time,” he recalled. “This machine has a whole myriad of contact wheels, from 2 inch to 20 inch, and is fitted with an inverter speed control. I use it to grind all my knives and also for hundreds of other grinding jobs. It’s probably the most used machine in my shop. It has a foot pedal to change belts and also some really bright LED lights on stalks so I can see where I’m grinding.”

The fourth machine is “Shaya,” Bertie’s “famous” 500-pound Massey power hammer. It was built in 1941 and he completely rebuilt it in 2000, a process that took eight years. 

“I make all my damascus on this hammer, Dragonskin, Nebula, and Fracture, as well as other laminar damascus. It is a gentle giant but packs a mean punch when at full speed. Hardly a week goes by when I don’t have two or three forging sessions.”

Murray Sterling 

Murray makes nothing but folders, including slip joints, linerlocks, and lockbacks. Among the latter is this fileworked and engraved straight-edge model in mother-of-pearl.

Murray Sterling turned 93 the first day of Spring and still makes knives like he’s 39. What are the most important pieces of knifemaking equipment for the self-described “old-school machinist” on the low side of 100 who’s been making knives for over three decades?

First are his four 2×72 belt grinders. He made three of them, including one he built 25 years ago that he uses 90 percent of the time. 

“I hollow grind and profile all my folders and finish all my folders with it,” he wrote. “The only other grinder I bought new was a square wheel in 1989. I only use it for 45-degree scales.”

Next on Murray’s list is his Taft Pierce surface grinder. “This is probably the most important machine in the shop for making folders, and that’s all I make now,” he wrote. 

The machine is over 50 years old and Murray bought it 20 years ago when it came available from a company his son worked for that was in the process of upgrading its machinery.

“In making folding knives, everything has to be flat,” Murray observed. “This machine is one of the best ways to achieve that. It has upgraded the quality of my folders by 100 percent. It also has a 2×72 belt attachment and, with a 60-grit belt, you can remove a lot of material fairly fast.”

Murray has four disc grinders, including two side-by-side models with 9-inch and 12-inch discs, the former with a 100-grit abrasive and the latter with a 320-grit one. Murray made the tables for the grinders 20 years ago. The motor for the 12-inch grinder is the original one from his square wheel grinder, the latter which he reoutfitted with a DC motor a couple of years after he bought it. The grinder on the fixed 45-degree table he uses for knife parts that need to be made square, such as backsprings for slip joints and lockbars.

The handiest machine in Murray’s shop is his Burgmaster drill press. He bought it in 1967 and uses it to drill 90 percent of the holes in his knives. It has six spindles, each of which runs at a different RPM. 

“I can set it up with a tap drill, clearance drill, and counter bore for .080-inch screws,” he wrote. “It makes things quick and easy. I would hate to do without any of these machines. I also have a lathe and make my own bushings and pivot pins.”

Brian Tomberlin

An example of Brion’s knives is his Nagabowie—a Japanese-style blade with hamon complemented by a bowie handle.

ABS master smith Brion Tomberlin makes a lot of hidden-tang knives in his shop in Norman, Oklahoma, and a set of handle broaches he got from fellow ABS master smith John Perry are a must-have for that style of knife construction.

“They do a great job of opening up the slot for the tang in handle blocks,” Brion observed. “I bought the first two from John way back when there was a Spirit of Steel knife show in Mesquite, Texas, probably his first or second batch of them. I still use them all the time. They’re very finely crafted tools.

“Another must-have tool for me and most makers is a set of calipers. In order to get things fitted correctly, such as guards and getting the measurements on things like the depth of clips even on both sides, you need to have accurate measurements. A good knifemaker thinks in thousandths and you need to be able to accurately measure them. So, I have calipers everywhere. I’ve got to have them.”

Brion uses a Foredom tool on every knife that leaves his shop. 

“It’s a super versatile tool,” he noted. “I’m sure everyone has used Dremel tools, especially the variable-speed models. But the Dremel tools wear out and I hear all the time that people keep buying them every two or so years because the tools stop working. So, save money and get the standard rotary-flex-shaft tool used in the jewelry trades. Just get a Foredom tool and you will not regret it.

“Mine is variable speed and reversible and that is what I suggest. I bought it from an old name in knifemaking supplies, Mick Koval [of Koval Supply], over twenty years ago. It’s still going strong. There is so much you can do with them and they have so many attachments. Rio Grande and Gesswein jewelry supply are knifemakers’ friends. I use this tool for guards, contouring buttcaps to match stag, polishing things, carving, etc. It has so many uses.”

Another tool Brion uses on every knife he makes is his trusty file guide. 

“The shoulder filing guide or just plain file guide should be standard in every maker’s shop,” he advised. “My main one is a carbide-faced model from Riverside Machine in DeQueen, Arkansas.

“You need to get the shoulders on a blade flat in order to get the guard to fit up correctly,” Brion wrote. A file guide will do that. “Also, with the carbide faces you can use the guide with grinding belts to get the plunges even. I bought this years ago when Uncle Al [Alton Lawrence of Riverside Machine] first started making them. It has served me well. You don’t have to have the carbide faces as there are hardened steel file guides too, but pay the extra money and get the carbide—you will not regret it.”

Rounding out Brion’s top knifemaking tools are his machinist squares.

“You have to be able to lay out lines and have them be true, everything from laying out guard slots to making sure things are 90 degrees, such as platens on grinders,” he advised. That’s where the machinist squares come into play. “You have to have them and they aren’t expensive. Making sure your layout lines are correct will help you make better knives,” Brion concluded. “Every knife shop should have them.”

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