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Danes to Dragons: Custom Hawks

Custom hawks and axes combine history, fantasy and imagination

From Danes to dragons, draft horses and drawing smoke, the axe and the hawk have become avenues of artistic expression for some of the most innovative artisans of sharp blades. Long a trusted and dependable companion on the trail, in the bush, around the camp and in the military, axes and hawks are utilitarian and versatile, both in form for their intended purposes and as striking examples of imagination, innovation and aesthetic appreciation.

Utilizing the best in materials and employing their long study of the axe and the hawk, several makers have produced notable works in recent years, among them Peter Pruyn, Tom Ward, Dave Armour and Bill Burke. Each has his own approach to the craft and adds perspective in producing works of incredible beauty.

“My motivation was to try something new,” related Armour, a knifemaker for about 12 years, fashioning hawks and axes for six years and turning his attention to full-time blade work only seven months ago. “In addition, a small, easy-to-carry axe can be a great complement to a hunting or other working knife. I call my style ‘sufficiently evil and deliberately casual.’ I take the function side of things—like heat treating and edge geometry—very seriously, but treat the rest of knifemaking as a chance to play and have some fun.”

With his Clydesdale Set, which includes both a 12.5-inch knife and a 17-inch axe, Dave Armour (inset) lets his ingenuity gallop through. The set is made with a single Clydesdale horseshoe that he obtained through his wife’s employment, involving a tour of Warm Springs Ranch in Missouri, home of the world famous Budweiser Clydesdales. (SharpByCoop axe image)

With his Clydesdale Set, which includes both a 12.5-inch knife and a 17-inch axe, Armour’s ingenuity gallops through. The set is made with a single Clydesdale horseshoe that he obtained through his wife’s employment, involving a tour of Warm Springs Ranch in Missouri, home of the world famous Budweiser Clydesdales.

“I used the sides of the shoe for the outer layers of the knife blade and the bottom for the body of the axe,” Dave said. “I wanted something rustic without looking primitive. So, I made choices like leaving the shoe nail holes unfilled and using a simple hardwood for the handles. I used W2 for the knife core steel and 80CrV2 for the axe bit. Anytime you’re using a unique material, it is stressful. If I messed this up, it wasn’t like I could just scrounge another Clydesdale shoe lying around somewhere.”

Armour, who plies his craft in Auburn, Illinois, uses the term “foundwood” for his handle material. Though he isn’t completely sure, he said he believes it is sassafras, liberated from the bottom of a box of cast-off exotic pieces in a local lumberyard.

The finished Clydesdale Set consists of the beautifully forged san-mai blades, foundwood handles, and a stainless steel bolster/guard. The blade measures 7.5 inches while the edged surface on the axe is 2.25 inches. Dave stated he would produce a similar set for $750 or the axe alone for $300—and he would enjoy the journey “tailoring my technique to the piece.”

 

MAGIC DRAGON

Forging knives since 1998, Burke received his ABS journeyman smith stamp at the 2003 BLADE Show. “I returned home, quit my job, and have been a full-time maker ever since,” he grinned. His Dragon Tomahawk is nothing short of breathtaking, and he acknowledges that the project was an investment of energy in his Boise, Idaho, shop. “This piece took three months of six- to eight-hour days, seven days a week for me to complete,” he noted. “I have a second piece flying around in my head now.”

The Dragon Tomahawk is 20.5 inches overall, with a 4-inch cutting surface of damascus and a curly maple handle. The head is wrought iron and 1018 mild steel forged into a “W’s” pattern, and the blade steel is 1080, 15N20 and 201 series nickel forged together to create Bill’s Dragon’s Breath pattern. (SharpByCoop image)

The second will be a show-stopper if it compares to the 20.5-inch masterpiece that sports a 4-inch cutting surface of damascus and handle of stout curly maple. “The head is wrought iron and 1018 mild steel forged into the ‘W’s’ pattern,” he commented. “The blade is 1080, 15N20 and 201 series nickel forged together to create my Dragon’s Breath pattern. The handle was first drawn and cut/carved from a piece of red fir, and then, after a few refinements, the pattern was drawn on the piece of maple and the handle made from that.”

Bill Burke lightly fire-etched the head of his Dragon Tomahawk, along with heat coloring the blade in niter salts to achieve a purple/blue-and-red coloration before it was welded to the dragon’s head. The teeth were raised from the steel of the head, and the tongue, inlaid into the blade, gleams in 24k gold. (SharpByCoop image)

Bill has been noted for his quality damascus, and with this piece took inspiration from the work of ABS master smith Joe Szilaski. “All my knives and hawks are forged by me in my shop,” Bill said. “I normally just get an idea of what I want to make and start forging. From almost the first moment that I made the Dragon’s Breath pattern, I knew I wanted to make a dragon-headed tomahawk, breathing fire down the blade of the hawk.”

The dazzling result includes a lightly fire-etched head “because dragons are born in fire and should look that way,” along with heat coloring the blade in niter salts to achieve a purple/blue-and-red coloration before it was welded to the dragon’s head. The teeth were raised from the steel of the head, and the tongue, inlaid into the blade, gleams in 24k gold. Bill indicated he would produce a similar piece for about $17,000, depending on embellishments.

 

NO PIPE DREAM

One of the most intriguing works by Peter Pruyn is his 15-inch Pipe Axe with ash handle, 4-inch blade and a bowl of hammered twist damascus. He forged the steel from layers of 1070, 15N20 and nickel. (SharpByCoop axe image)

Peter Pruyn was self-taught for quite a while after taking up knifemaking when he lost a valued knife he had carried for years. He later learned the stock removal method from Gene Martin and also attended an ABS bladesmithing class. “That definitely made me a more diverse maker, and it opened me up to forging different types of edged weapons and tools,” he said. From there, he worked with ABS master smith Red St. Cyr, who taught him to forge a tomahawk from a ball-peen hammer.

Through 14 years making knives—12 of those full time—Peter developed an interest in Viking blades, and he has sold a number of pieces on BladeGallery.com. One of his most intriguing works is his 15-inch Pipe Axe with ash handle and 4-inch blade and bowl of hammered twist damascus. He forged the steel from layers of 1070, 15N20 and nickel.

“I was forging an axe for the BLADE Show about seven or eight years ago when I had the idea of making it into a pipe axe, which is similar to a pipe tomahawk,” Peter remembered. “It really only has a larger blade.”

While working on the Pipe Axe, Peter greeted a friend who had come to his shop to work on the electrical setup. “He spotted the head when I removed it from the etchant,” Pruyn recalled, “and immediately claimed it.  I was trying something different on this particular one. I did a very long etching process, and it gave a very deep, rough texture and an antiquated look to the steel. I did the Viking rings on the handle, but I also wanted to put some rings on the pipe bowl to give it a better look.”

The effect was certainly achieved, and Peter successfully tested it using cigar tobacco. “It worked quite well,” he concluded. He said a similar model would run $700.

 

HALVDAN SWUNG ME

Christened “Halvdan Swung Me,” the Dane Axe by Tom Ward is based on Viking lore and representative of the weapons Viking mercenaries may have wielded in the service of the emperor of Constantinople, today known as Istanbul. His list price for a similar axe: $3,200. (SharpByCoop axe image)

After recently relocating his enterprise, along with his wife’s furniture business, from Carbondale, Illinois, to Istanbul, Turkey, Tom Ward looks forward to future custom orders. Among these may well be a request for a piece similar to his hefty Dane Axe.

When in design school in Boston, Tom took an elective course on forging damascus and bladesmithing taught by ABS master smith J.D. Smith (see May and June issues of BLADE®). “I really fell in love with the process and the idea of making high-quality objects to last someone’s entire life or longer,” he related. “I also loved the history of it and what you could learn through those venues. J.D. was my mentor for about four years before I left school and Boston. My work was fairly independent until 2017, when I started my degree at Southern Illinois University and spent three years researching damascus steel with Richard Smith in Carbondale.”

One of the most significant results of Ward’s career in steel, the Dane Axe, christened “Halvdan Swung Me,” is based on Viking lore and representative of the weapons Viking mercenaries may have wielded in the service of the emperor of Constantinople, today known as Istanbul.

“The phrase ‘Halvdan was here’ is carved into the bannister of the balcony of the Hagia Sophia in Istanbul,” Ward remarked. “So, he was the inspiration for the piece and the name. The shape is not exactly like any Dane axe but serves the same idea with an angled broad blade and beard, and a thin cross section as most war axes had. The angle of the blade is to deliver a deeper chopping or swinging cut, and it is the same cutting concept as the curve of a saber. The forward point is also hypothesized for stabbing, and the beard for hooking legs and shields.”

Damascus legend Daryl Meier sold the wrought iron, salvaged from a bridge that was torn down in Illinois, for inclusion in the Dane Axe steel combination, and encouraged Tom’s pursuit of pattern welding. The Dane Axe haft, fashioned from sturdy hickory and ash laminate, extends beyond 5 feet.

“The pattern welding on the blade is sort of an East meets West thing,” Tom commented, “with traditional wolf’s tooth from northern Europe and the Persian chain patterns, as well as the Byzantine tendency for geometric patterns with the chevrons.”

These exceptional craftsmen are among many who have explored the addition of hawks and axes to their repertoire. They set the bar high and bring additional interest to another creative frontier.

Above: Rudy Dean’s pipe hawk features a 4.5-inch blade of twist damascus and a handle of curly English walnut. The smoke  hole plug is damascus and the mouthpiece and eye cap are ancient walrus ivory. (SharpByCoop image)

 

How To Determine The Best Angle To Sharpen

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What determines the best sharpening angle? The answer is one that plagues knife neophytes and old hands alike.

“The best angle of sharpening is one of those very intriguing topics that many have explored but most have come up with different answers,” states Jake Broce, online marketing coordinator for A.G. Russell Knives. Agrees Kyle Crawford, brand manager for Work Sharp, “The answer is often different for everyone.”

He says the two keys are knife type/use and edge retention/maintenance. In fact, all of our story sources cited the intended use of the knife as a deciding factor. For tough chores such as chopping or batoning, a wider angle is best. “Generally, the wider the angle of edge, the more steel is behind it, which increases the edge’s toughness,” Broce observes. “For kitchen knives that see light-duty cutting food on cutting boards, or a task-specific hunting knife like a camping knife, a low angle is ideal,” counters Crawford. By “low” he means an edge angle between 15 and 20 degrees.

Edge angle also affects edge retention. “If you sharpen your heavy-use EDC knife to a low angle such as 15 degrees, it will be incredibly sharp,” Crawford says, “but the trade-off you are making is edge retention and durability.” Conversely, he adds, if you sharpen at a wider angle, such as 25 degrees, the edge will still be very sharp but you gain improved edge retention and, thus, eliminate the need for more frequent maintenance.

“The edge angle is seldom impacted by the blade grind,” says Work Sharp’s Kyle Crawford. “Be mindful that the sharpener you are using may not be able to replicate the blade grind. But for most of us, sharpness is the goal, not maintaining the exact factory grind type.” The DMT Duo-Sharp sharpener does the honors here.
“The edge angle is seldom impacted by the blade grind,” says Work Sharp’s Kyle Crawford. “Be mindful that the sharpener you are using may not be able to replicate the blade grind. But for most of us, sharpness is the goal, not maintaining the exact factory grind type.” The DMT Duo-Sharp sharpener does the honors here.

However, Kendra Tobler, marketing communications manager for Benchmade Knife Co., indicates grades of blade steel also factor in as well. “A harder steel with higher yield strength can be ground to a small included angle with less worry about rolling or deforming the edge,” she says. “Conventionally cast steels with large carbides are better suited to larger included angles.” This is done so for edge durability.

A prime example of Tobler’s point is Benchmade’s 15017-1 Hidden Canyon Hunter, a compact drop-point fixed blade in premium CPM S90V stainless steel well known for its extreme edge-holding ability. Benchmade uses its SelectEdge 14-degree included edge on the knife. It is ground thinner because S90V is a high-yield-strength steel that can retain its strength with a thinner edge without deforming or chipping. Blade thickness is a factor as well. “Thin blades are much easier to sharpen to low edge angles than thick knives,” Crawford states. “The thicker the blade, the more material you will have to remove to create a low edge angle.” And it usually takes time to thin down a thick blade. As he warns, “If you choose to sharpen a low edge angle onto a thick blade, be prepared to be patient.”

Sharpening To Steel Grade

“Modern super steels have really changed the game for low angles and edge retention,” Crawford says. By this he means
blades of lower quality steel are prone to low edge retention as well as edge deformation and damage incurred from use. Higher quality steels have the high yield strength that enables them to be sharpened with lower edge angles, resist deformation and damage, and have higher edge retention overall. Crawford specifically cites CPM S45VN and CPM 154 as types of high-yield stainless steels. For lesser grades of steel, opt for a wider angle to save you from having to deal with damaged edges and/or frequent edge maintenance. Any steel designated as CPM (manufactured by Crucible Industries) or any other high end/high-performance steel can be taken down to lower edge angles for enhanced performance. Such steels include M4, 20CV, S30V, S35VN, S45VN, S60V, S90V, S110V, CRU-WEAR® and the CPM version of D2.

Knives come with a standard edge from the factory, around 22 degrees inclusive. The edge is sharp and durable, and a good middle-of-the-road angle that is a good balance between durability and cutting ease. The Work Sharp Ken Onion Elite sharpener is set here to sharpen at 22 degrees.
Knives come with a standard edge from the factory, around 22 degrees inclusive. The edge is sharp and durable, and a good middle-of-the-road angle that is a good balance between durability and cutting ease. The Work Sharp Ken Onion Elite sharpener is set here to sharpen at 22 degrees.

Lesser grades of steel that should not be taken down to acute angles mostly are found on entry-level to mid-grade factory knives, and some higher-end non-CPM steels found in high-end factory knives. Such stainless steels would include 440A, AUS-8, 8Cr13MoV, 1.4116 and VG-10. The high-end non-CPM stainless steels would be 154CM, ATS-34 and 440C. Also, any grade of carbon (non-stainless) steel should be treated like this as well. Examples would be 1095, 5160, D2, O1, A2 and so forth. If the steel’s specs do not state that it is a CPM steel, avoid applying acute edge angles and stick with wider ones to be safe.

Consequently, it is very important to educate yourself on the different grades of steel and their performance characteristics and edge retention qualities. Such information will further help you understand how the steel type will perform and how maintenance should be handled.

Sharpening To Blade Grind

The many different types of blade grinds are largely influenced by the knife’s intended use. As Tobler notes, “The bevel grind and the sharpening angle should complement each other.” For instance, hollow-ground blades have thinner edges. “This complements a small included angle,” she states. “A convex edge provides plenty of material behind the edge for strength and support and works well with a larger included angle.” Adds Broce, “The blade grind determines how much steel is behind the edge. More steel behind the edge improves edge stability, whereas less material behind the edge can improve the pass-through” of the material being cut.

Blade thickness is a factor as well. “Thin blades are much easier to sharpen to low edge angles than thick knives,” Crawford states. “The thicker the blade, the more material you will have to remove to create a low edge angle.”
Blade thickness is a factor as well. “Thin blades are much easier to sharpen to low edge angles than thick knives,” Crawford states. “The thicker the blade, the more material you will have to remove to create a low edge angle.”

Crawford takes a different tack. “The edge angle is seldom impacted by the blade grind,” he says. “Be mindful the sharpener you are using may not be able to replicate the blade grind. [Author’s note: Hollow grinds are converted to flat grinds when using a stone, or too convex grinds when sharpening on a flexible abrasive belt.] But for most of us, sharpness is the goal, not maintaining the exact factory grind type.”

Know The Use

“The required cutting task affects the angle,” Broce says. “Chopping requires good edge stability, so an increased edge angle is necessary.” He also explains that finer chores such as slicing and dicing work better with more acute angles due to the precision cutting. “Whittling introduces more variables than normal knife use,” he states. In other words, whittling exerts a lateral force on the blade and, therefore, the cutting edge. “Generally, you want a thicker blade stock with a thin edge [on a whittling knife],” he sums up. Agrees Tobler, “Smaller angles, like our SelectEdge, work best for finer, delicate slicing cuts.” The primary goal for Benchmade’s 14-degree SelectEdge is for field dressing, and the acute-angle edge slices through thicker hide and meat almost effortlessly.

Knives come with a standard edge from the factory, around 22 degrees inclusive. The edge is sharp and durable, and a good middle-of-the-road angle that is a good balance between durability and cutting ease. Some users are harder on a knife and require the larger edge angle. Nonetheless, with task-specific knives of high-yield-strength steels for hunting/field dressing, you may opt for a more acute edge angle, anywhere between 15 and 20 degrees.

Establishing The Sharpening Angle

How should you go about establishing the edge angle when you sharpen? A safe bet is to invest in a sharpener that sets and maintains the edge angle for you—all you have to do is set the sharpener to the desired angle.

Lesser grades of steel such as the 7Cr17MoV stainless of the Gerber Tri-Tip should not be taken down to an acute angle.
Lesser grades of steel such as the 7Cr17MoV stainless of the Gerber Tri-Tip should not be taken down to an acute angle.

“Angle guides are tried and true and solve one of the biggest sharpening challenges—establish the angle and be consistent,” Crawford says. Cautions Broce, “The first time you use [a guide kit] on your knife will usually take the longest, as your edge angle adjusts to the way you use the sharpener.” The angle guide kits subtract the science of maintaining a consistent angle, so all you need do is concentrate on getting the edge sharp. The kits have been a game-changer for consumers who struggle with freehand sharpening on a bench stone.

Another good tip, regardless of which sharpener you use, is the tried-and-true black marker trick. Using a permanent black marker with a wider chisel tip, color the edge bevel on both sides of the blade. The goal is to sharpen the blade,
removing the black marker ink from both sides. When you accomplish this, your edge angle is correct and you should have a sharp blade.

“The goal is to remove all of the ink in one swipe,” Crawford says. “If you are removing the marker at the cutting edge, your edge angle is too high and you are micro-beveling.” From there adjust your edge angle to a lower degree and take a few more passes to see how the ink is being removed. “It is a process of trial and error,” Crawford notes.

According to Jason Broce of A.G. Russell Knives, “The blade grind determines how much steel is behind the edge. More steel behind the edge improves edge stability, whereas less material behind the edge can improve the pass-through.”
According to Jason Broce of A.G. Russell Knives, “The blade grind determines how much steel is behind the edge. More steel behind the edge improves edge stability, whereas less material behind the edge can improve the pass-through.”

Tobler is another proponent of the marker method. “It helps for matching the edge angle already on the blade when resharpening,” she observes. You can use the method in conjunction with one of the guide kits even if the kit holds the angle constant for you. The method enables you to see how much more you must sharpen off in order for the edge bevel to be reestablished. In this regard, you’re using it to determine how much more you have to go as opposed to if you’re holding the angle correctly.

Another tip is to sharpen in a well-lighted area. Good visibility is very important and key to doing a thorough, well-executed sharpening job. And if you use the marker method a lot, abundant lighting helps you see clearer without eye strain.
Finally is sharpener selection. You can use any quality sharpener as long as it fits the steel type. The key here is to select a sharpener you feel very comfortable in using.

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Four Battle Tough Military-Style Fixed Blade Knives

Today’s military-style fixed blades are ready for duty. These four are certainly ready to earn their stripes.

What Are The Top Military-Style Fixed Blade Knives:

The history of cutlery has many different facets but none any more glorified than the fixed-blade knives that have seen battle for centuries. Fixed blades are still a major part of our fighting forces’ need for strong steel and they’ve become more diverse since the modern tactical age began in the early-to-mid 1990s.

Condor Tool & Knife’s Neck Gladius

One thing hasn’t changed: such knives must perform duties outside of combat. An example is Condor Tool & Knife’s Neck Gladius, a diminutive version of the classic Roman combat sword. Designed by writer/outdoorsman and BLADE University instructor Joe Flowers, its double-edged blade is handsomely ground in Condor’s favorite blade material: 1075 high carbon steel. The black-paracord-wrapped handle has a tail at the base. A black Kydex neck sheath includes a nice length of paracord for neckwear.

The black Kydex sheath of the Neck Gladius includes a suitable length of paracord for neck wear.
The black Kydex sheath of the Neck Gladius includes a suitable length of paracord for neck wear.

One of the best uses I’ve found for small neck knives is preparing tinder as a firestarter. The neck knife makes for an excellent companion to a larger knife for doing detail work, so I put the Neck Gladius to work doing just that.

Hitting my sweet spot, a pine forest north of town, I used the small blade to dig out some nice chunks of pine resin, which burns nice and long as tinder. I complimented the pine resin with some fine pine shavings to complete the kit. The little Condor will handle other small tasks as well, such as cutting paracord to length. “Handy” is its middle name!

Condor Tool & Knife Neck Gladius
Designer: Joe Flowers
Blade Length: 3.14″
Blade Material: 1075 high-carbon steel
Handle Material: Baracord wrap
Weight: 2.12 ozs.
Overall Length: 6.06″
Sheath: Kydex with paracord lanyard
Country Of Origin: El Salvador
MSRP: $54.98

DoubleStar Blades Chico Diablo X

Designed by BLADE® field editor Kim Breed, the Chico Diablo X from DoubleStar Blades is, as you might expect, tough as nails. It is a medium-sized sheath knife with a harpoon-pattern blade. A deep index finger groove extending from the bottom/front of the checkered scales into the tang adds grip when getting down to business. The black Boltaron sheath has a real-deal Tek-Lok for carry options. Weight is a manageable
6.24 ounces.

A deep index finger groove extending from the bottom/front of the checkered scales into the tang of the DoubleStar Chico Diablo X adds grip when getting down to business.
A deep index finger groove extending from the bottom/front of the checkered scales into the tang of the DoubleStar Chico Diablo X adds grip when getting down to business.

The knife’s size is perfect for medium-duty field tasks such as dressing game, prepping meals, cutting rope and working wood. It’s not heavy enough for chopping but is a serious slicer. I tested the blade across the grain on a 4.5×2.25-inch slab of cold corned beef brisket. Despite the blade being shorter than the chunk of beef, the Nitro-V stainless steel glided through the brisket, taking off one clean quarter-inch slice after another. The Chico Diablo X is a well-built multi-tasker worth every penny of its surprisingly affordable price tag.

Doublestar Blades Chico Diablo X
Designer: Kim Breed
Blade Length: 3.75″
Blade Material: Nitro-V Stainless
Handle Material: Black G-10 with green G-10 liners
Weight: 6.24 ozs.
Overall Length: 8″
Sheath: Black Boltaron with Tek-Lok attachment
Country Of Origin: USA
MSRP: $149.99

Kizlyar Supreme Senpai

The Kizlyar Supreme Senpai is the longest knife of the test group, including a tanto blade in more of a traditional Japanese curved-tip style. The handle is spare of curves save for a slight finger groove and short guard. The scales are nicely rounded and Kizlyar provides a sandwiched matching green synthetic belt sheath for carry.

The Senpai includes a traditional Japanese tanto blade. The handle has nicely rounded scales spare of curves save for a slight finger groove and a short guard. The knife comes with a matching green synthetic belt sheath.
The Senpai includes a traditional Japanese tanto blade. The handle has nicely rounded scales spare of curves save for a slight fi nger groove and a short guard. The knife comes with a matching green synthetic belt sheath.

Given its weight and slim blade profile, I liked the Supreme Senpai for slicing and shaving from a utility standpoint. I roughed out a seasoned hardwood tent peg using a small hatchet, and tested the blade at finetuning the pointed tip and shaving the sides. The long blade came in handy as I could pull it through while slicing and shaving rather than simply pushing it downward against the tough hardwood—my reasoning being, if it could handle stout wood, simpler chores like meal prep and cutting rope would be a snap. The Supreme Senpai blade performed well shaping the challenging wood, leaving no doubt it could be handy around camp.

Kizlyar Supreme Senpai
Blade Length: 6.75″
Blade Material: AUS-8 stainless
Handle Material: OD green Kraton/ABS plastic
Weight: 10.3″
Overall Length: 12″
Sheath: Polyamide Nylon
Country Of Origin: Russia
MSRP: $150

Halfbreed Blades Medium Infantry Knife

How brutish is the Aussie-made Halfbreed Blades Medium Infantry Knife? Consider this—it’s around just one ounce shy of the other three test knives combined in weight! The blade is a whopping .23-inch thick at its thickest, features 1.5 inches of serrations from the tang forward, and has a black, rust-resistant Tefl on coating. The ample handle scales are “chunked” black G-10 and there’s a wicked skull crusher. The sheath has rear attachments for MOLLE (Modular Lightweight Load-carrying
Equipment) or belt carry.

The Halfbreed Medium Infantry Knife incorporates brutish .23-inch blade steel. The author pulled it through five lengths of 3/8-inch rappelling rope in one clean slice using the forward plain edge portion of the blade.
The Halfbreed Medium Infantry Knife incorporates brutish .23-inch blade steel. The author pulled it through five lengths of 3/8-inch rappelling rope in one clean slice using the forward plain edge portion of the blade.

This overbuilt brute is a handful capable of chopping, slicing and shaving. Given its near three-quarter-pound weight it will no doubt chop, but the serrations somewhat limit the chopping ability of the blade’s plain edge portion. (Serrated edges will chop but it’s hard on them, and resharpening the teeth is a royal pain.)

I tested the knife at slicing and started with lengths of ⅜ -inch synthetic rappelling rope. Working my way up, I was able to slice cleanly through five lengths of the rope side-by-side before I ran out of rope. The handle offered superb grip throughout the testing process. The Halfbreed entry has the ability to perform heavy-duty camp chores like
shelter building, chopping branches for firewood and shaving wood.

Halfbreed Blades Medium Infantry Knife
Blade Length: 6.69″
Blade Material: Bohler K110 D2
Handle Material: Black G-10
Weight: 17.08 ozs.
Overall Length: 11.77″
Sheath: Black Kydex
Country Of Origin: Australia
MSRP: $335


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Fit and Finish 101: How to know it when you see it on a knife

By Pat Covert

Fit and finish is bandied about so often in cutlery circles it’s almost become one word, pronounced something like fittenfinnish. A newbie collector who hangs around seasoned custom knifemakers, purveyors and collectors soon learns the “fit-and-finish thing” is a mighty nice trait for the knives in his or her stable to have.

All that being said, is fit and finish the key to a knife being all it can be, or does a knife exhibiting it simply look nicer and cost more? Or does the answer lie somewhere in between? We recruited a panel of authorities to help sort through it all, including purveyors Neil Ostroff of True North Knives, Dave Ellis of Exquisite Knives, Dan Delavan of Plaza Cutlery, and seasoned custom maker Tim Britton.

We started by asking our authorities how they define fit and finish. Britton, who makes highly finished customs, said, “There should be no adhesive or solder showing anywhere. No gaps in inappropriate places. Metal-to-metal joints should be indiscernible. And no visible scratches or grind marks, period. One thing custom knifemakers should be able to do well,” he observes “is finish metal.”

Having the grinds match on each side of the blade as on Marcus Lin’s Andalusian bowie is an indication of fine fit and finish.

In addition to being a purveyor, Ellis also is a retired ABS master smith and knows fit and finish from the maker’s point of view as well. “I define fit and finish of a custom knife to mean is it overall appealing to the eye,” he begins, “are there any obvious gaps in guard or handle fitting, is it a design that will truly work?” Ellis stressed that good, sound design is a factor. “The first thing I look for is the overall appearance. Is the design clean? Is there an organic flow? How does it feel in the hand in different grips? Then I look at the finer details such as guard fit, blade finish, handle design and comfort,” he explains. “As an ABS master smith I also look at things like edge geometry, tapered tangs and plunge cuts. All of these should be [executed properly] in a piece with excellent fit and finish.”

Equality of all aspects on both sides of the knife is one sign of top fit and finish. Greg Cimms achieves it on his kitchen knives.

“Fit and finish is a standard required for all knives,” Ostroff says. “It used to be almost exclusively for custom knives—which are at a higher price level—but more and more the buyers are demanding the same standard for a factory or mid-tech knife which will sell for a remarkably lower price. Fit and finish is generally a well-centered blade—in the case of a folder—no blade play in either direction, flush-fitting bolsters, and a blade finish as the maker intended. By this I mean one cannot expect a stonewashed blade, or handle, not to have scratches. Recently the matter of the strength of the detent has become an issue—again, another subjective item.”

The late Bruce Bingenheimer centered the blade of his folder in the closed position (right), splitting the gold anodized standoffs right down the middle. Note the symmetry between each side of the knife (left) and the slick fit between bolster and handle material (center).

“The criteria for fit and finish depend on the expectations of the buyer,” Delavan qualifies. “Plaza Cutlery also believes design as well as craftsmanship is important. Most important is the design. It has to make sense to me. Any guards should be clean with no gaps, bevels should be the same and no 2-inch glitches. Also, handles have to be clean to the tang or guard with no gaps.”

According to Tim Britton, metal-to-metal joints should be indiscernible. Note the partial knife image second from left. The seam between the blade and backspring of BLADE Magazine Cutlery Hall-Of-Fame® member Ron Lake’s tail-lock interframe is invisible.

 

PERFORMANCE

Does fit and finish affect a knife’s performance? “Poor fit and finish will really show when a knife is put to hard use,” Ellis advises, pointing out potential problems such as hot spots from badly designed and finished handles, guards or buttcaps with sharp edges, bad edge geometry that might cause the blade to dull quicker and be difficult to remove from the sheath, and so on.

David Mirabile achieves a nice, tight fit between the habaki (collar) and tsuba (guard) of his Asian-style piece.

Britton’s take was interesting, to say the least.

“One of my first knives was made in 1972. It was ugly and poorly finished,” he recalls. “[BLADE Magazine Cutlery Hall-Of-Fame® member] Frank Centofante helped me sell the knife to a hunting guide from Montana. The guide later wrote to me wanting four more just like it. The knife skinned and dressed three elk before needing sharpening. Steel was Latrobe D2 and Paul Bos did the heat treat. Fit and finish had little or nothing to do with function. Quality of steel, heat treat, grind and sharpening angle were much more relevant.”

Mark Bartlett gets the bolster of case-hardened mild steel and gold-anodized titanium spacers to meld seamlessly with the curly koa handle of his fixed fighter.

“A good finished knife just has a better feel, but a lot of people will not use it,” Delavan notes. “A knife with a lot of cosmetic issues can still be a good tool, and there are makers that don’t worry about those details. Most makers say a knife is meant to be used, not to sit in a safe.” Ostroff tends to agree. “Performance is not typically an issue [with fit and finish]. For example, a knife with an off-centered blade will still function as well as one that is centered—but the customer has the right to get what he or she wants, so we do whatever it takes to make them happy.”

Top fit and finish includes the knife exhibiting no visible scratches or grind marks. Tim Britton’s lockback follows this dictate. As Tim noted, “One thing custom knifemakers should be able to do well is finish metal.”

 

F&F: OVERRATED?

Are there cases where fit and finish is overrated? In other words, are there knives that perform very well even though they may not have the polish of an expensive model but have excellent heat treat, blade geometry, comfort and a more affordable price?”

“Fit and finish is not overrated when trying to satisfy the buyer,” Ostroff opines, “but taking out the collector/safe-queen members of our community, all knives are meant to cut, and all will do so if built to industry standards.”

“I have seen a few knives that performed well with poor fit and finish,” Ellis says. “Usually if a maker takes the time to finish their piece to tight tolerances, they also have taken the time to be sure that the piece has a credible heat treat, edge geometry and an overall good feeling in the hand.” Adds Delevan, “Many of the small production companies do a good job. Fit and finish is good, not perfect, but you have an excellent tool at a more affordable price.”

Note how each grind, bolster and slab mirrors its opposite on the Fenix fixed-blade hunter by Evgeny Khokhlov.

 

WHAT do YOU WANT?

Our authorities made excellent points for and against performance being a factor in fit and finish. Though there were several substantive points about design, in this writer’s opinion it isn’t really a fit-and-finish issue. Design is, of course, very important because no matter how well a knife is made, if the design is poor so will be the performance. From an aesthetic standpoint fit and finish is everything, but, as Delavan points out, many collector-grade knives become safe queens, never seeing action in the field.

A good analogy here would be comparing a Bark River Knives fixed blade to a comparably sized one made by ESEE Knives. Both companies have a huge, extremely dedicated following. Bark River’s fare is finely finished while the ESEE knives are more roughly done, but the latter are half the price or more of the former, depending on materials. Will both knives perform well? You better believe it. Both have stellar performance records. It really depends on whether you want to pay extra for a nicely finished knife or a rough finished one. Beauty is in the eye of the beholder and both do their job in spades.

Bottom line is you have some very good options available—and choices make the world of knives go around!

Note the tight fit with no gaps between the color-case-hardened bolster, stainless steel spacers and stabilized ringed gidgee handle of Steve Filicietti’s bowie.

Best Big Knives: Four Behemoths That Are A Cut Above The Rest

Looking for a blade that can handle jobs and and small? These four giants are some of the best big knives out there.

What Are The Big Knives:

Little knives are convenient to carry but, if you have a lot of work to do, big knives are it. I’ve lived and worked with indigenous peoples in Latin America and Southeast Asia and found that wherever folks live close to the earth, they use big knives—machetes, parangs, goloks, bolos and the like. They use them for everything from rough work such as cutting poles and opening coconuts, to dressing out pigs and game, to delicate work such as slicing mangoes.

The advantage of the big blade was illustrated to me one day when I was working alongside a villager who, with his bolo and its 14-inch blade, cut wood for a fire, bamboo poles for a cooking rack, and lopped off a banana leaf on which he filleted two large fish and sliced them thin as a sushi chef—all in the time it took me to bring down a few stalks of bamboo with my hair-shaving-sharp Randall Model 1.

We reviewed the test knives with that standard in mind. We chopped and split wood and sliced meat and tomatoes. We also, just because, cut hanging rubber hose and slashed through water-filled plastic bottles.

A tree branch succumbs to the reflective blade of the Boker Arbolito El Gigante. It cleaved 2-inch pine saplings in one stroke
A tree branch succumbs to the reflective blade of the Boker Arbolito El Gigante. It cleaved 2-inch pine saplings in one stroke

Boker Arbolito El Gigante

The Boker Arbolito El Gigante is a handsome classic bowie with a stonewashed blade, comfortable handle and nice leather sheath. Balance is excellent, all very much in the bowie tradition. Construction is top quality; so is performance. It cleaved 2-inch pine saplings with one stroke. The quarter-inch-thick spine was brought down to a well-supported edge fine enough to slice tomatoes thin enough to see light through the slices. We slashed rubber hose and the water bottles with ease.

Like all well-designed and crafted bowies, this is a versatile all-around knife.

BOKER ARBOLITO EL GIGANTE
BLADE LENGTH: 9.25”
BLADE STEEL: Bohler N695 stainless
BLADE THICKNESS: .24”
BLADE GRIND: Flat
BLADE FINISH: Stonewash
HANDLE THICKNESS: .94”
HANDLE MATERIAL: Green Micarta®
WEIGHT: 15.75 ozs.
OVERALL LENGTH: 14.75”
SHEATH: Leather
COUNTRY OF ORIGIN: Argentina
MSRP: $229


The KA-BAR Gunny chomps into dry pine. Its forward weight and blade design promote effi cient chopping
The KA-BAR Gunny chomps into dry pine. Its forward weight and blade design promote effi cient chopping

KA-BAR Gunny

The KA-BAR Gunny is a hybrid design that resembles a bolo. I suspect R. Lee Ermey, the unforgettable Gunny who serves as the knife’s namesake, spent some time in jungles because this combination chopper/slicer’s performance is on par with village-forged bolos I’ve used in Southeast Asia, and that’s a high compliment. Its forward weight and terrific blade design promote efficient chopping. We cut through 3-to-4-inch-thick saplings with two strokes. We took down a tree with a 6-inch-thick truck just because we could. After the chopping, the blade was still sharp enough for camp kitchen work. The belly, good balance and fine edge combined to make slicing meat and vegetables a pleasure. Slashing hanging rubber hose and the water bottle were a piece of cake. The comfortable handle lends itself both to heavy chopping and fine meat cutting, which is unusual.

The Gunny is an excellent all-around bush knife. The sheath has a pocket for a sharpening stone, which was not included with the review model.

KA-BAR GUNNY
DESIGNER: R. Lee “Gunny” Ermey
BLADE LENGTH: 9.75”
BLADE MATERIAL: 1095 Cro-Van carbon steel
BLADE WIDTH: 2”
BLADE THICKNESS: .2”
BLADE GRIND: Flat
HANDLE WIDTH: 1.5”
HANDLE THICKNESS: .94”
HANDLE MATERIAL: Wood
WEIGHT: 15.29 ozs.
OVERALL LENGTH: 15.5”
SHEATH: Leather
COUNTRY OF ORIGIN: USA
MSRP: $292


The Medford Knife & Tool Bonfire slashed through water-filled plastic bottles with more consistency than the other review blades
The Medford Knife & Tool Bonfire slashed through water-filled plastic bottles with more consistency than the other review blades

Medford Knife & Tool Bonfire

The Medford Knife & Tool Bonfire came from the maker absolutely razor sharp! The blade design is interesting in that we do not often see a contemporary styled drop point and hollow grind on such a big blade. I don’t know its Rockwell hardness, but the steel is hard and tough.

It was just as razor sharp after we put it through its paces as when we started. The fine edge made for a very good slicer and slasher and lopped off thin branches with one cut. The hollow grind tended to bind when chopping wood, though that’s to be expected—hollow grinds aren’t chopping designs. It’s better to think of this knife as a well-designed and crafted big knife rather than a bush tool such as a panga or kukri. It sliced rubber hose with a snap of the wrist and slashed through water bottles with more consistency than the other review blades, and cut meat just fine. You probably could dress out a bear with it. Use it as a big knife on soft materials and you won’t be disappointed. It comes

MEDFORD KNIFE & TOOL BONFIRE
BLADE LENGTH: 8.25”
BLADE MATERIAL: CPM 3V carbon steel
BLADE THICKNESS: .24”
BLADE GRIND: Hollow
HANDLE THICKNESS: .64”
HANDLE MATERIAL: G-10
WEIGHT: 19.16 ozs.
OVERALL LENGTH: 13”
SHEATH: Nylon
COUNTRY OF ORIGIN: USA
MSRP: $450


TOPS Bestia

The TOPS Knives Bestia’s kukri-styled 13-inch blade and hefty weight made it the blade of choice for serious chopping or, as the author puts it, “zombie cleaving.”
The TOPS Knives Bestia’s kukri-styled 13-inch blade and hefty weight made it the blade of choice for serious chopping or, as the author puts it, “zombie cleaving.”

The TOPS Bestia is just a beast. A kukri-styled 13-inch blade and hefty weight make it the blade of choice for serious chopping or zombie cleaving. We hacked through a 3-inch sapling with one stroke, and used it to clear a stand of saplings and brush. The handle remained comfortable during an hour or so of work. Heavy as a small hatchet, it is more versatile and safer in use, especially in thick brush.

During many survival classes, I’ve seen more injuries from hatchets than from big blades with their longer cutting edges. Given its heft, blade design and chopping ability, the Bestia is surprisingly usable in the camp kitchen. We found it could slice meat quite well, allowing for adjustments in maneuverability due to its blade length.

TOPS KNIVES BESTIA
DESIGNER: Leo Espinoza
BLADE LENGTH: 13”
BLADE MATERIAL: 1095 carbon steel
ROCKWELL HARDNESS: 56-58 HRC
BLADE WIDTH: 2.25”
BLADE THICKNESS: .25”
BLADE GRIND: Flat
HANDLE WIDTH: 2.125”
HANDLE THICKNESS: .97”
HANDLE MATERIAL: Green Micarta®
FRAME/LINER: Micarta
WEIGHT: 1 lb., 13.18 ozs.
OVERALL LENGTH: 19.5”
SHEATH: Kydex
COUNTRY OF ORIGIN: USA
MSRP: $300

VERSATILE BUSH TOOLS

If you haven’t spent much time with a big blade, try one. Work with it for a while. Direct close attention to your work and you’ll find a good big blade to be a terrific, versatile bush tool.

Also Read:

2021 BLADE Show West Factory And Custom Knife Award Winners

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See who took top honors in Long Beach for the 2021 Blade Show West Awards.

BLADE Show West took place Oct. 8-9, 2021, at the Long Beach Convention Center in Long Beach, Calf. It was the show’s inaugural year in California and drew custom makers, manufacturers and collectors from around the county.

It also drew an impressive cadre of entrants for the BLADE Show West Factory and Custom Knife Awards. For Factory Knives, awards were given in five categories, while the Custom Knives awarded six categories.

The Factory section was evaluated by a panel of undisclosed industry experts who judged the blades on a number of factors, including utility, design, creativity, materials and other traits. The Custom section was judged by a number of expert knifemakers along similar lines.

Factory Knife Award Winners

Best Tactical and Best In Show


Civivi Tamashii designed by Bob Terzuola, SharpByCoop Image

Purchase it here:

Best Hunter


Bradford Knives M390 Guardian 4, SharpByCoop Image

Purchase it here:

Best Big Knife


Bradford Knives REX 45 Fillet, SharpByCoop Image

Best Folder


Pro-Tech Malibu Custom Limited Edition w/textured bronze aluminum handle, SharpByCoop Image

Best EDC


Monterey Bay Knives wharncliffe flipper folder, SharpByCoop Image

Custom Knife Award Winners

Best Folder and Best In Show


Mike Tyre mosaic damascus folder, SharpByCoop Image

Best Damascus

Mike Shindel Merovingian Sword in a 4-bar Turkish twist, and a random-pattern wrap-around edge of 1084 and 15N20 carbon and nickel-alloy steels, SharpByCoop Image

Best Slip Joint


Luke Swenson split-backspring whittler, SharpByCoop Image

Best EDC


Tobin Hill one-blade trapper, SharpByCoop Image

Best Chef’s Knife


Nicholas Berkofsky/Fell Knives 7.5-inch Protein Petty, SharpByCoop Image

Best Hunter


Mike Shindel integral bolster hunter, SharpByCoop Image

Stay up-to-date on Blade Show Events by signing up for the Blade Show Newsletter Here.


Also Read:

Last Little Mester of Sheffield: Remembering Stan Shaw

The author remembers Stan Shaw as only she can

By Grace Horne

Sometime in the early 1990s, a journalist—to the chagrin of the handful of other knifemakers also still working in Sheffield, England—described Stan Shaw as “The Last Little Mester,” and the title stuck until Stan’s passing in February. Stan made many fancy pocketknives but “Little Mester” was never simply a title that denoted mastership of a craft skill.

Historically, workers in the Sheffield cutlery industry were notoriously independent. As the industry moved from craft-based to industrialization, nearly all cutlers were on piece-work and would rent space in the workshop—a yard of bench or a “trough” for grinding. Work came from other workers, and each worker did a very specific task on the knife before it was passed to the next worker. The process was efficient because of the hyper-specialization of all of the workers in the chain. There was a complicated, ever-changing network of subcontracting, renting, supplying and rivalries, but no one learned all the processes to make a knife—there was no concept of sole-authorship.

In her thesis, Sally-Ann Taylor* states that the “differing opinions regarding the status of the little mester reflected the actual diversity in his possible position and role. Some felt that the title implied that his enterprise should involve him in a certain number of commercial risks and liabilities. Sometimes he was an actual workman himself, obtaining orders from larger factors, merchant or manufacturers, and then employing a few men to help him … sometimes even these workers would employ others beneath them, but usually only members of their own family—particularly women and children.” Hence, little mesters were small-scale flexible employers, recruiting workers to supplement their own labor as required.

In 1844, a commentator on the cutlery trades stated that “there are several modes of conducting the manufacture, but the factory system is not one of them … there is no large building, under a central authority, in which a piece of steel goes in one door and comes out at another converted into knives, scissors and razors. Nearly all the items of cutlery made at Sheffield travel about the town several times before they are finished.”**

 

HE KNEW at 14

Stan didn’t come from a cutlery background. He was born in 1926 in a small village outside Sheffield, and, after seeing a market stall of knives, decided at 14 that that was what he wanted to do. By chance, he walked into the prestigious company, Ibberson, and spoke to the owner, Billy Ibberson.

Pointing to a showcase displaying the firm’s best pocketknives, Stan said he’d like to learn how to make such knives. As Stan recalled, “Billy then fetched up one of the cutlers, Ted Osbourne—a little bloke about 5 feet or so tall—and asked, ‘Will you have him?” He said, ‘Yes.’ And I started on the Monday at an apprentice’s wage of 10 shillings a week.”

When Stan joined the firm, the old patterns of working had long gone; “little mesters” and “factors” had morphed into the more familiar patterns of factory working, with all the workers employed by the company and paid a wage. He was one of the last apprentices to be taken on and his curiosity about the entire process of making folding pocketknives was insatiable. As he moved through Ibberson and other companies over the years, he actively approached other workers to learn their processes as well as his own. It was this breadth of training that made him unique and was vital to him in later life.

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A sampling of Stan Shaw’s pocketknives with richly fileworked blade spines and backsprings. Look close and you can see the Maltese crosses for which Stan was so well known. (image by Carl Whitham, Sheffield)

 

THEIR PATHS CROSS

By the beginning of the 1980s, the contraction of the Sheffield cutlery industry was such that there were no more companies left to employ him, so he set-up his own workshop in Garden Street. It was there, 10 years later, that our paths crossed.

I had made a set of three folding knives for a college project and hadn’t been able to find anyone still making traditional Sheffield slip joints to ask for advice. A couple of years later, I heard Stan being interviewed on the radio and realized that I still desperately wanted to learn to make knives. I packed up my workshop in London and moved to Sheffield to persuade him, in person, to take me on as his apprentice. He welcomed me into his workshop but said that he was nearly 70 and too old for an apprentice.  Instead, he offered me his bucket of old, handforged blades and springs, told me to select a handful and “go and figure it out yourself because it’s not that hard.” He would always be there to help if I got stuck.

Stan Shaw as he appeared in the early 1990s. (Geoffrey Tweedale image)

A few years ago, when I was gently teasing him about still having a 10-year waiting list for his knives, he said, “I should have taken you on then, lass, you’d just about be useful to me now!” So, for all the times our paths crossed, for all the gentle encouragement and for completely changing my life’s path when I was 23 years old, thank you, Stan.

Stan was not a “little mester.” He was a master and was proud that he could make his knives from start to finish, a concept that would be completely alien to Sheffield knifemakers a hundred years ago.

Stan Shaw, whose career of making classic pocketknives spanned almost 80 years, passed in late February at the age of 94.

He started work for W.G. Ibberson in Sheffield, the old knifemaking capital of England, in 1941. Apprenticed to Fred and Ted Osborne, men Stan described as the two best cutlers in Sheffield, he eventually succeeded them in 1954 as the company’s top maker of pocketknives. Though the Sheffield knife industry was in rapid decline, he continued making knives, renting an old workshop in 1983 and becoming an independent cutler.

As Stan moved through Ibberson and other companies over the years, he actively approached other workers to learn their processes as well as his own. It was this breadth of training that made him unique and was vital to him in later life. (image by Carl Whitham, Sheffield)

As an independent he did it all in the making of his pocketknives, and he did it all quite well. As he said in “Stan Shaw: Little Mester of Sheffield” in the May 1994 BLADE: “I have to do everything now because there are no forgers, grinders, scissor-makers and so on left. My earlier experience with Ibberson’s has proved invaluable in that respect. All my knives are hafted, ground and assembled by me. It’s harder work but the satisfaction is greater. Scissors, files, punches, shields, shackles, handles, scales, bolsters—the list is endless—but each part is made by me on these wheels and dollies with only hacksaws, files and a few other traditional tools, such as my parser. The only job I don’t do is the occasional engraving I have done on the bolsters.”

His knives are testaments to the classic exhibition pieces, many with a host of blades and other tools and implements. In 2003 he became an honorary freeman of the Company Cutlers and in 2017 was awarded the British Empire Medal. As late as 2019, into his 90s, he continued to clock in bright and early in the mornings to make pocketknives at Kelham Island Museum. In the interim he served as a mentor to many makers, including award-winner Grace Horne, among others.—by BLADE® staff

Editor’s note: An award-winning knifemaker from Sheffield, England, the author currently makes traditional folders. For more information contact her at Dept. BL9, The Old Public Convenience, 469 Fulwood Rd., Sheffield, United Kingdom, S10 30A [email protected], gracehorn.co.uk. Also: Steven and Kylie Cocker, Instagram @steven_cocker_sheffield; Michael May www.michaelmayknives.com; and/or Michael and Ashley Harrison plus apprentice at A Wrights & Sons www.penknives-and-scissors.co.uk.

*Tradition and Change: The Sheffield Cutlery Trades 1870-1914; Sally-Ann Taylor

**The Penny Magazine Supplement, April 1844, p.168; Thomas Allen

 

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