温胡知新・On Ko Chi Shin

A true and accurate understanding of the past is an important step towards a good future. 温胡知新 (on ko chi shin) is an expression that most directly translates to, “study the old to know the new”. This project represents the current progression of my work based on the… Continue reading →

Komori~san back in the forge

Komori~san and his talented crew came to the island and spent a couple of days getting footage in the forge and of the final assembly of a tanto. They set up all their own lighting in the forge, and along with a couple of cameras and a sound… Continue reading →

Aikuchi Tanto Koshirae

A custom koshirae for a small antique tanto blade belonging to a client. Crimson lacquered samegawa handle, fukiurushi horn fittings, a silver mekugi, and polished black lacquer scabbard in a classical aikuchi style. Materials for the custom red and black aikuchi style koshirae mounting include lacquered samegawa over… Continue reading →

Pacific Yew Forest Kotanto

This custom kotanto finds a balance between the humble satoyama style and a classical tanto with a striking combination of forged copper, natural orange hardwood, and black urushi lacquer. The blade began as a reclaimed harrow tooth and was hand forged in a charcoal fire, differentially hardened using… Continue reading →

Bladesmithing at the Museum Forge

Forging a custom forest kotanto in the swordsmith forge. The starting material was a harrow tooth, the finished blade is hirazukuri, mitsu mune, 140mm / 5.5″ nagasa, with a sturdy 6.5mm motokasane. The finish will be tsuchime (hammer texture) so there was no filing or polishing before yaki-ire, which was done at my forge for the dim and consistent light conditions.

Process: Making the Fittings – Aikuchi Tanto Koshirae

The fuchi and koiguchi are from a reclaimed buffalo horn souvenir, the kurikata is from a reclaimed horn button, the wrapping is rawhide samegawa, the mekugi is copper and silver. All of the parts are first shaped and fit, then the samegawa is wet formed to the handle contours, dried, and then attached with sokui (rice paste glue). After the scabbard and handle are lacquered, the horn parts will be polished and attached with sokui as well. The mekugi cap is soldered on with hard silver solder in the charcoal forge. carving the inside | carving the outside | final work

Process: Carving the Tsuka & Saya – Aikuchi Tanto Koshirae

In this video the tsuka is carved first, starting with the fuchi end and then the kashira area, carving the profile outlines and then removing the material in between before carving the final shape and sculpting the details. The saya is next, first dimensioning the blank is to approximate size and then profiling the koiguchi and then the kojiri, removing the material and carving as close as possible to the final shape using kanna and kiridashi. Finally any remaining high points in the curves are smoothed with a fine rasp. carving the inside | making the fittings | final work

Process: Carving the Inside – Aikuchi Tanto Koshirae

In this video the tsuka is carved first, starting with the omote side and then the ura, carving each half from the mune to the ha. The saya is next, starting with the omote and then the ura, each half beginning with the fitting of the blade (from the mune towards the ha) and then the fitting of the habaki area (koiguchi). Finally the halves are glued together with rice paste glue, wrapped with leather cord, and wedged tightly to dry overnight. The first half is almost real time, the repeat steps edited out during the second half. The wood is hounoki, carve carefully and check often! carving the outside | making the fittings | final work

Making a Handle for a Japanese Swordsmithing Hammer

Traditional Japanese swordsmithing hammers have rectangular eyes with no taper. The handles are not wedged but are held in place by a compression fit involving careful shaping, hand forged wood, and soaking in water. The wood is shaped a couple of mm oversized, compressed by hammering, and then… Continue reading →

Crossed Heart Forge

Charcoal forged classical tanto & fusion style takedown knives crafted by hand from reclaimed steel and natural materials using traditional techniques.

Author Archives: davej