David's school, "Studio 4" (which ironically is in room #3 in the building) was in an old metalworks building in industrial Seattle. Drafty and cold, we soon forgot the chill as we got down to business. David had already laser cut knife blanks for us, and we had a choice of style.....skinner, hunter, or Santoku style kitchen knife. I chose the hunter.
David took the time to explain geometry, steel characteristics, Metallurgy of carbon steel, safety precautions, etc. Then, down to work. Our first duty was to establish our plunge line and initial bevel, as well as rough shaping the handle. Standing at the grinder I was pretty happy to have a bracket that established the exact grinding angle for the plunge line . I would've freaked out if I was told to do it "by eye". hahahaha!
David explains and demonstrates at the furnace
Knife held in the salt pot
Day Two: The polishing begins. After the tempering, we each had stations where we stood with sanding sticks, starting with 400 grit sandpaper and gradually going to 1200. Funny, just as I thought the steel was beginning to polish up, scratches that weren't there before, revealed themselves. I thought I was going to be sanding and polishing for hours.....which was pretty much the case. Two hours of patient polishing, and I had a shiny blade in comparison to the dull salt pot/oven tempered color that I started out with.
Where the heck did those scratches come from?
After the polish, which evened out the harsh bevel, it was time to epoxy the scales to the handle. Dave mixed the epoxy for each of us, as "two part epoxy was a tricky thing....if you don't mix it right, it will screw everything up and you'll need to clean off all the gunk and start over". Well, no one wanted that, so we welcomed the fact that he was willing to mix the epoxy for us.
Ready for epoxying to tang....
This underside part was all lopsided until Dave helped me fix it....
After a final profiling of the blade, we all had Dave put the final sharpening on each blade. We all watched intently, and I tried to take mental pictures of how he did it....even down to how he took his stance in relation to the grinder and blade. Each of our blades were sharp.....mine not "crazy sharp" as Dave noted that since I wanted a utilitarian knife, he left enough "tooth" so as to cut through rope and twine, whittle wood, etc. Now my students who made Santoku style kitchen knives.....those knives were crazy sharp. Like "cut paper thin slices of tomato" sharp.
The youngest of our group, a 14 year old kung fu student of mine, turned out a beautiful hunting knife. Dave was there with Isaac all the way, guiding him through the power tools. I was so proud of this young man making his own knife, with the scary power tools! His mom, the Tai Chi student who initially set up this workshop, was a proud mama hen too.
The finished product!
All and all....a wonderful weekend. It felt great to know that a little bit of "me" was in this blade...and no amount of money will buy this blade from me. Now....to save up my $$ for more classes. The "great grinding" class sure sounds like fun......