Making a damascus fighter (tons of pictures)

[Ariel Salaverria]

This will go to the Knifemaking section of my website when it's done.

This is the sketch of the custom knife to make.

http://www.aescustomknives.com.ar/images/clydetz1_big.jpg


We arranged the following:

- 3/16" thick blade of a San Mai damascus with O1 in the middle.
- Coppered damascus bolsters.
- 1/8" thick sheep stag handle slabs.
- 1" diameter forefinger ring.


This is from the meeting with another knifemakers and tracer-san. I prepared 3 damascus billets to test the drop hammer Alberto (one of the knifemakers) built and to see if I could get some extra help on this damascus, as it's going to be pretty big.

Customers's billet is the one next to the hammer.

http://www.aescustomknives.com.ar/other/forja2_big.jpg


The bottom one.

http://www.aescustomknives.com.ar/other/forja1_big.jpg


Putting it on the oven and hammering it a bit.

http://www.aescustomknives.com.ar/other/forja3_big.jpg

http://www.aescustomknives.com.ar/other/forja4_big.jpg

http://www.aescustomknives.com.ar/other/forja5_big.jpg


Testing the drop hammer.

http://www.aescustomknives.com.ar/other/forja6_big.jpg

http://www.aescustomknives.com.ar/other/forja7_big.jpg

http://www.aescustomknives.com.ar/other/forja8_big.jpg

http://www.aescustomknives.com.ar/other/forja9_big.jpg

http://www.aescustomknives.com.ar/other/forja10_big.jpg


The drop hammer didn't have enough weight installed to hammer strong enough, but I managed to get the billet a little longuer though.

In the middle of the forging the billet started to get loose from the supporting bar from the heat and hammering, so I had to reinforce the welding.

http://www.aescustomknives.com.ar/other/autogena1_big.jpg

http://www.aescustomknives.com.ar/other/autogena2_big.jpg

http://www.aescustomknives.com.ar/other/autogena3_big.jpg

http://www.aescustomknives.com.ar/other/autogena4_big.jpg

http://www.aescustomknives.com.ar/other/autogena5_big.jpg


Here you can see Ruben Calo using the drop hammer :)

http://www.aescustomknives.com.ar/martinete1.mpg

http://www.aescustomknives.com.ar/martinete2.mpg


I kept on forging the next day at my workshop, and just to show you guys that this is not an exact science, after hammering the billet, I discovered it was a bit shorter than what I needed, so I'm gonna have to forge a new billet for this and use this for another knives.

I could strech it to fit, but then the thickness wouldn't be the ordered, so it was not an option.

http://www.aescustomknives.com.ar/images/clydetz17_big.jpg

http://www.aescustomknives.com.ar/images/clydetz18_big.jpg


This is the making of the canister with the different steels inside to place later in the oven to heat it (O1 in the center, and layers of 1010 and 1070 surrounding it)

http://www.aescustomknives.com.ar/images/clydetz19_big.jpg

http://www.aescustomknives.com.ar/images/clydetz20_big.jpg

http://www.aescustomknives.com.ar/images/clydetz21_big.jpg

http://www.aescustomknives.com.ar/images/clydetz22_big.jpg



Forging time again :)

This is how I made the hole on the steel and then hammer it to accomodate it to the right position.

http://www.aescustomknives.com.ar/images/clydetz23_big.jpg

http://www.aescustomknives.com.ar/images/clydetz24_big.jpg

http://www.aescustomknives.com.ar/images/clydetz25_big.jpg

http://www.aescustomknives.com.ar/images/clydetz26_big.jpg

http://www.aescustomknives.com.ar/images/clydetz27_big.jpg


After I had the holes and flatened steel, I cutted a stencil in paper, a little bigger than the knife so I have some room later for the grinding stage and glued it to the steel with contact cement.

http://www.aescustomknives.com.ar/images/clydetz28_big.jpg


On this detail, you can see the stencil hole matches the steel hole (bad choice of background for the picture)

http://www.aescustomknives.com.ar/images/clydetz29_big.jpg


Here I am, taking the steel bar into shape with a hand grinder (I don't use laser or plasma cutters or saws)

http://www.aescustomknives.com.ar/images/clydetz30_big.jpg

http://www.aescustomknives.com.ar/images/clydetz31_big.jpg

http://www.aescustomknives.com.ar/images/clydetz32_big.jpg


After I finish that, the steel has the shape, but it's still very rough.

http://www.aescustomknives.com.ar/images/clydetz33_big.jpg


Smoothing it with a bench grinder.

http://www.aescustomknives.com.ar/images/clydetz34_big.jpg


Knife blank

http://www.aescustomknives.com.ar/images/clydetz35_big.jpg

http://www.aescustomknives.com.ar/images/clydetz36_big.jpg





Here's a little preview of the grinding lines (Those curves were really hard to make)

http://www.aescustomknives.com.ar/images/clydetz37_big.jpg

Check out the red lines, my sugestion for teh customer was that the front bolster covers all of that, so he can have a better finger rest with a firmer grip (he agreed with that :) )

If you look at the grinded part, you can see the O1/damascus line on the middle :D




This was the hardest knife to grind I have ever make, and I'm really proud of how it turned out :D

I made some bevels wider than on the original design to show the damascus and O1 patterns better.

http://www.aescustomknives.com.ar/images/clydetz38_big.jpg

http://www.aescustomknives.com.ar/images/clydetz39_big.jpg

http://www.aescustomknives.com.ar/images/clydetz40_big.jpg

http://www.aescustomknives.com.ar/images/clydetz41_big.jpg

http://www.aescustomknives.com.ar/images/clydetz42_big.jpg

http://www.aescustomknives.com.ar/images/clydetz43_big.jpg



Here's how you prepare the sheep stag to be used on the knife.

I was going to do this tomorrow, but I did it tonight so tomorrow I can just start working on the handle itself when I get up :)


First I cutted the stag in 3 parts so I can place it on a pot

http://www.aescustomknives.com.ar/images/clydetz44_big.jpg


I boiled the pieces of stag so they become elastic.

http://www.aescustomknives.com.ar/images/clydetz45_big.jpg


Right after the boiling bath, ready to be flattened.

http://www.aescustomknives.com.ar/images/clydetz46_big.jpg


On the horizontal press.

http://www.aescustomknives.com.ar/images/clydetz47_big.jpg


Flattened stag, already marked with the aproximate shape of the handle slabs to be cutted.

http://www.aescustomknives.com.ar/images/clydetz48_big.jpg


Cutted slabs and damascus steel marked for the bolsters.

http://www.aescustomknives.com.ar/images/clydetz49_big.jpg

http://www.aescustomknives.com.ar/images/clydetz50_big.jpg



A part of the handle making process :)


I use a tin alloy bar to add a film to the back of the bolster so I can weld it later to the knife.

http://www.aescustomknives.com.ar/images/clydetz52_big.jpg


Same treatment on the knife.

http://www.aescustomknives.com.ar/images/clydetz53_big.jpg


I press both pieces in position and then I heat it with a torch to the melting point of the alloy (aprox 270 C)
When it colds, the welding is perfect, so I can take it off the grip.

http://www.aescustomknives.com.ar/images/clydetz53_big.jpg

http://www.aescustomknives.com.ar/images/clydetz53_big.jpg


Regards,


Ariel

[BenDibble]

i think i have an idea who this is for? that is if this fellow finished his planing on his knife. looks awefully familiar. and as always, incredibly work! :gogdog: :gogdog:

[Spufnik]

Awesome work there Ariel :gogdog: That is going to be one hell of a wicked custom knife!!! I can't wait to see the handles on

[borinquen]

damn i got fatigued just looking at the pictures,you must have incredible stamina to forge and grind these knives :gogdog:
i love seeing the detailed process of making the knives :gogdog:
beautiful work.

[BennytheBlade]

Love those curvy grinds.
:gogdog:

[Clydetz]

You're amazing, Ariel! I really look forward to your picture posts! :thumbsup:

[Mr.LaBella]

I cannot wait to see her clydetz! :gogdog:

[BenDibble]

i knew it! glad to see it finally made it to production stage. :gogdog: :gogdog:

[Clydetz]

It's way to mean to be a 'her'... it's a 'him'! :D

[BenDibble]

yea, women don't fight. :razz:

[Clydetz]

yea, women don't fight. :razz:

Oooohhhhh! I wouldn't say that! They just fight... well... er... different! :-D

[Ariel Salaverria]

This is how I secure the scales on knives so I don't rely only on the pins/screws :)


Placing the scales on place to test the fit (check out the oversized slabs so I have extra room to polish it properly later) The blade isn't coppered, just looks that way because of the lightning.

http://www.aescustomknives.com.ar/images/clydetz55_big.jpg


Putting poliester resin on the back of the scale.

http://www.aescustomknives.com.ar/images/clydetz56_big.jpg


On the press for a proper glueing

http://www.aescustomknives.com.ar/images/clydetz57_big.jpg

http://www.aescustomknives.com.ar/images/clydetz58_big.jpg



Regards,


Ariel

[Ariel Salaverria]

Sanding the bolsters and slabs.

http://www.aescustomknives.com.ar/images/clydetz59_big.jpg

http://www.aescustomknives.com.ar/images/clydetz60_big.jpg


Almost ready to place it again in acid, to get the pattern on the bolsters and a little more in the blade.
All the drawings are a long process, as I have to protect this parts now for the acid, and later to copper just the bolsters I have to protect the slabs again and the blade and spine on the handle so that doesn't get coppered too.

The knife is still missing the thumb serrations.

http://www.aescustomknives.com.ar/images/clydetz61_big.jpg


Showing the point of balance.

http://www.aescustomknives.com.ar/images/clydetz62_big.jpg



Regards,


Ariel

[Clydetz]

To quote the Grand Funk Railroad... looks like this one is "...getting closer to my home..."! Outstanding, Ariel! You have taken my miserable drawing & with all your talents have turned it into a work of knife art! :thumbsup:

[BenDibble]

that is wonderful. after seeing clydetz's sketches and now the almost finished knife i am amazed. Beautiful work. Good thing Clydetz isn't the knife maker. :razz:

[Ariel Salaverria]

How about a preview of the just etched bolsters before coppering them?

http://www.aescustomknives.com.ar/images/clydetz63_big.jpg


Instead of screws, I used 7 copper pins to secure the slabs to match the coppered bolsters.

Regards,


Ariel

[TheBadGuy]

Just start drawing your stuff up now b/c this gentleman isn't afraid to attempt anything and it always comes out awesome :gogdog: :gogdog:

I know I am looking forward to my next knife from Ariel!! And even though its not even on its way to me yet, I am thinking up some designs I want him to have a crack at :gogdog:

[TheBadGuy]

WOW, You snuck that last picture in on me while I was typing. LOVE the addition of thos pins!!!! And the damascus on the bolsters is awesome, Can't wait to see them coopered. :gogdog:

[Ariel Salaverria]

Thank you Jason! :)

Ariel

[Clydetz]

I can't think of any more metaphors, Ariel... your craftsmanship is just unbelievable! Those homemade copper mosaic pins are a great touch & will tie into the coppered damascus bolsters fantastically! My hat is off to you, sir! :thumbsup:

[Spufnik]

That is a wicked looking piece there!!!! :gogdog: :gogdog: I can't wait to see it!!!!!

[bart-1]

Man ole man, GREAT job!! Very impressive!! You are extremly talented!!

You the :kingkaxt: !!

[Ariel Salaverria]

Tomorrow... :cool:

Ariel

[Ariel Salaverria]

I finished it :)

http://www.aescustomknives.com.ar/images/clydetz64_big.jpg

http://www.aescustomknives.com.ar/images/clydetz65_big.jpg

http://www.aescustomknives.com.ar/images/clydetz66_big.jpg

http://www.aescustomknives.com.ar/images/clydetz67_big.jpg

http://www.aescustomknives.com.ar/images/clydetz68_big.jpg

http://www.aescustomknives.com.ar/images/clydetz69_big.jpg


Some bigger images:

http://www.aescustomknives.com.ar/images/clydetz64_bigger.jpg

http://www.aescustomknives.com.ar/images/clydetz66_bigger.jpg


Regards,


Ariel

[TheBadGuy]

WOW............................................... .................................................. .................................................. ................
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[Clydetz]

Uh huh... WOW! Ain't never seen anything like it Ariel... that be BODACIOUS my friend! :thumbsup: :love:

[Spufnik]

(shakes head in amazement)............ :gogdog: :gogdog:

[BenDibble]

shakes head in amazement and envy. Clydetz, you lucky dog you. Now someone needs to buy another knife from Ariel so we can see his masterful craftsmanship again. :gogdog:

[Ariel Salaverria]

Thank you very much, I'll do my best with the sheath too.

Regards,

Ariel

[Ariel Salaverria]

I just started a new thread for the sheath :)

http://www.jerzeedevil.com/forums/viewtopic.php?t=1022
Regards,

Ariel

[nate3993]

Dude, i didn't think your knife was gonna come out that incredible. You're dam good. keep up the good work

[Billy Stewart]

Great work Ariel i can see why that was such a hard project, lots of curves and grind lines to match up. You did an excellent job, and congrats to the knew owner!!:chuck::kingkaxt:

[knifepuppet]

Ariel your surely a talented balde maker.

I enjoy your WIP thread, these pictures are great.

Thanks for sharing~~~ :hmmrf:

[RoyalM]

That is a piece of art and even better it's a knife.

I bash about with old files and moding cheaper knives, then you see a true craftsman do work like this.

Great thread, great pics and great knife.

[Clydetz]

What a pleasure to read Ariel's thread again! Your knife, sheath and display box are still getting WOW's from relatives and friends. Thanks a million for tackling that project, Ariel! http://i18.photobucket.com/albums/b114/Clydetz/thumbsup1.jpg

[General Specific]

Anyone have a valid link to the sheath thread? The one posted by Ariel is no longer working...

Thanks,

Dave

[Blastmaster1972]

Interesting thread! Only a little ancient isn't it?

Ariel is always good for some nice work.

Kind regards,

Jos

[Clydetz]

Anyone have a valid link to the sheath thread? The one posted by Ariel is no longer working...

Thanks,

Dave

Check out Ariel's website... all kinds of good stuff! Here is the link to Ariel's sheath and the display box too... http://www.aescustomknives.com/docs/knifemaking9.htm

[General Specific]

Check out Ariel's website... all kinds of good stuff! Here is the link to Ariel's sheath and the display box too... http://www.aescustomknives.com/docs/knifemaking9.htm

Thanks Clydetz!

Dave

[cardoso5fr]

The knife is not my cup of tea, but you impressed me each time, i'm always amazed to see your work.

[Clydetz]

Don't blame Ariel if you don't like the knife... he took my drawing and made it pretty much to my specs. And yes, Ariel is quite a knowledgeable and artistic knifemaker!

[cardoso5fr]

I don't blamed him at all :), it's just not my cup of tea. I'm always amazed by the talent and the result Ariel obtain :D

[culpeper]

This is a classic thread. Good work.