Design a Custom Tanto


Hand Forged Tanto: Choose a style, hand crafted on Vancouver Island.

Step 1 – choose the style

satoyama rustic or full classical style.


Hand Crafted Tanto: Choose the mounting, hand crafted on Vancouver Island.

Step 2 – choose the type

hand crafted traditional mountings.


Heirloom Tanto: Design your own, hand crafted on Vancouver Island.

Step 3 – customize your tanto

made from reclaimed and natural materials.

Choose the Style


Satoyama Style: Choose a Blade Type

Design Your Own: Mountain Tanto

$1400$2300

The wider profile of the mountain style tanto is inspired by a kamakura sword and has a more deeply curved tip (fukura-tsuku) and shorter drop point.

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Description

Design a custom tanto mounted in the rustic satoyama tanto style of your choice. More info: Design Your Own Custom Tanto.

Variation shown: hammer finish blade, copper chisagatana guard, natural brown fukiurushi on handle, and natural brown ishimeji lacquered scabbard.

Island Blacksmith: Charcoal forged tanto from reclaimed files.
Island Blacksmith: Charcoal forged tanto reclaimed from farm equipment.
Island Blacksmith: Charcoal forged tanto reclaimed from files.
Island Blacksmith: Charcoal forged knives from reclaimed steel.
Tsuchime (Hammer Finish)

Island Blacksmith: Charcoal forged knives from reclaimed steel.
Kaji Togi (Stone Finish)
Island Blacksmith: Charcoal forged knives from reclaimed steel.
Togi (Polished Finish)

Island Blacksmith: Traditional techniques and natural materials.
Fukiurushi (Wiped Surface)

Island Blacksmith: Traditional techniques and natural materials.
Ishimeji (Stone Surface)

Island Blacksmith: Traditional techniques and natural materials.
Antique Crimson Ishimeji

Blade Finish

  • tsuchime – hammer texture (as-forged surface shows marks of hammer and fire)
  • kaji togi – stone finish (blade is smoothed with files and a coarse stone before hardening)
  • togi – polished (blade is smoothed with fine stones after hardening)

Habaki

  • habaki (blade collar, improves hold in the scabbard)
  • without habaki (not recommended for large blades)

Guard Style

  • hamidashi (almost flush with the handle)
  • chisagatana (slightly extended around all sides)
  • nata (slightly extended/flared on the edge side)

Fuchi Style

  • cord wrap ferrule (lacquered cotton or hemp)
  • forged copper open ferrule
  • forged iron open ferrule

Kurikata Placement

  • none (no cord loop, smooth kaiken style scabbard)
  • tanto (loop on omote side for edge-up cross draw)
  • nata (loop on ura side for edge-back right hand side carry)

Lacquer Finish

  • fukiurushi (smooth wiped-on layer, often in natural brown colour)
  • ishimeji (stone-like texture created with urushi and crushed tea leaves)
  • negoro (“worn-look” fukiurushi done with two colors)
  • lacquered cord wrap (full handle wrap, saturated with urushi)
  • or some combination (including giving unlimited creative license to the maker)

Lacquer Colour

  • natural (a red-brown when used for fukiurushi, a dark chocolate when used for ishimeji)
  • black (shows some wood through with fukiurushi, very deep black with ishimeji)
  • antique crimson (very deep red/brown with plum undertones)
  • black and red (streaked “negoro” or texture fill, varies greatly)
  • natural and black (streaked “negoro” or texture fill, more subtle)
  • natural and red (streaked “negoro” or texture fill, more subtle)
  • or some combination (including giving creative license to the maker)

Measurements

Nagasa (blade length): 170-200mm
Motokasane (blade thickness): 5-7mm
Motohaba (blade width): 28-32mm
Sori (curve): uchizori
Nakago (tang): 100-110mm
Tsuka (handle): 110-120mm
Koshirae (overall): 320-340mm

Potential Raw Materials

Blade: reclaimed file steel, harrow tooth steel, spring steel
Habaki (blade collar): forged copper bus bar
Tsuba (guard): forged copper bus bar, salvaged steel, or wrought iron
Handle and scabbard: Nootka Cypress, hemp or cotton cord wrap
Finish: natural urushi lacquer, crushed tea leaves
Mekugi (removable peg): Bamboo

Design Your Own: Forest Tanto

$1500$2450

The narrower blade profile of the forest style tanto is based on a yoroidoshi tanto and has a takenoko (bamboo shoot) shape and gradual drop point.

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Description

Design a custom tanto mounted in the rustic satoyama tanto style of your choice. More info: Design Your Own Custom Tanto.

Variation shown: hammer finish blade, copper chisagatana guard, natural brown fukiurushi on handle, and natural brown ishimeji lacquered scabbard.

Island Blacksmith: Charcoal forged tanto from reclaimed files.
Island Blacksmith: Charcoal forged tanto reclaimed from farm equipment.
Island Blacksmith: Charcoal forged tanto reclaimed from files.
Island Blacksmith: Charcoal forged knives from reclaimed steel.
Tsuchime (Hammer Finish)

Island Blacksmith: Charcoal forged tanto from reclaimed steel.
Kaji Togi (Stone Finish)
Island Blacksmith: Charcoal forged tanto from reclaimed steel.
Togi (Polished Finish)

Island Blacksmith: Traditional techniques and natural materials.
Fukiurushi (Wiped Surface)

Island Blacksmith: Traditional techniques and natural materials.
Ishimeji (Stone Surface)

Island Blacksmith: Traditional techniques and natural materials.
Antique Crimson Ishimeji

Blade Finish

  • tsuchime – hammer texture (as-forged surface shows marks of hammer and fire)
  • kaji togi – stone finish (blade is smoothed with files and a coarse stone before hardening)
  • togi – polished (blade is smoothed with fine stones after hardening)

Habaki

  • habaki (blade collar, improves hold in the scabbard)
  • without habaki (not recommended for large blades)

Guard Style

  • hamidashi (almost flush with the handle)
  • chisagatana (slightly extended around all sides)
  • nata (slightly extended/flared on the edge side)

Fuchi Style

  • cord wrap ferrule (lacquered cotton or hemp)
  • forged copper open ferrule
  • forged iron open ferrule

Kurikata Placement

  • none (no cord loop, smooth kaiken style scabbard)
  • tanto (loop on omote side for edge-up cross draw)
  • nata (loop on ura side for edge-back right hand side carry)

Lacquer Finish

  • fukiurushi (smooth wiped-on layer, often in natural brown colour)
  • ishimeji (stone-like texture created with urushi and crushed tea leaves)
  • negoro (“worn-look” fukiurushi done with two colors)
  • lacquered cord wrap (full handle wrap, saturated with urushi)
  • or some combination (including giving unlimited creative license to the maker)

Lacquer Colour

  • natural (a red-brown when used for fukiurushi, a dark chocolate when used for ishimeji)
  • black (shows some wood through with fukiurushi, very deep black with ishimeji)
  • antique crimson (very deep red/brown with plum undertones)
  • black and red (streaked “negoro” or texture fill, varies greatly)
  • natural and black (streaked “negoro” or texture fill, more subtle)
  • natural and red (streaked “negoro” or texture fill, more subtle)
  • or some combination (including giving creative license to the maker)

Measurements

Nagasa (blade length): 200-220mm
Motokasane (blade thickness): 5-7mm
Motohaba (blade width): 24-28mm
Sori (curve): uchizori
Nakago (tang): 100-110mm
Tsuka (handle): 110-120mm
Koshirae (overall): 350-370mm

Potential Raw Materials

Blade: reclaimed file steel, harrow tooth steel, spring steel
Habaki (blade collar): forged copper bus bar
Tsuba (guard): forged copper bus bar, salvaged steel, or wrought iron
Handle and scabbard: Nootka Cypress, hemp or cotton cord wrap
Finish: natural urushi lacquer, crushed tea leaves
Mekugi (removable peg): Bamboo


A charcoal forged blade, water quenched with clay, sharpened with waterstones, and finished simply and humbly in the age-old style of farm and foresting tools used in managing satoyama, the borderlands between village and wilds.


Classical Style: Choose a Mounting Type

Design Your Own: Kaiken Tanto

$2500$3300

The kaiken tanto was designed to be carried in the fold of a kimono and is characterized by a smooth profile and unadorned lacquered exterior.

SKU: N/A Categories: ,

Description

Design a custom tanto mounted in the classical style of your choice. More info: Design Your Own Custom Tanto.

Variation shown: 8″ blade, yasurime habaki, forged copper seppa, natural brown ishimeji finish, and optional kurikata cord loop.

Island Blacksmith: Charcoal forged tanto from reclaimed files.
Island Blacksmith: Charcoal forged tanto reclaimed from farm equipment.
Island Blacksmith: Charcoal forged tanto reclaimed from files.
Island Blacksmith: Traditional techniques and natural materials.
Ishimeji (Stone Surface, in antique crimson)

Island Blacksmith: Traditional techniques and natural materials.
Negoro (worn look, in natural and black)

Island Blacksmith: Traditional techniques and natural materials.
Matte (smooth matte polish, in black)

Habaki Texture

  • yasurime (linear texture)
  • tsuchime (hammer peened texture)
  • ishimeji (stone/frosted texture)
  • or give unlimited creative license to the maker

Seppa Material

  • none (lacquer only)
  • forged copper (water pipe)
  • forged brass (door push plate)

Lacquer Finish

  • ishimeji (stone-like texture created with crushed tea leaves)
  • tsuya keshi (smooth matte surface layer)
  • negoro (“worn-look” matte surface done with two colors)
  • or give unlimited creative license to the maker

Lacquer Colour

  • natural (a red-brown when smooth, a dark chocolate when used for ishimeji)
  • black (very deep)
  • antique crimson (very deep red/brown with plum undertones)
  • black and red (streaked “negoro” or texture fill, varies greatly)
  • black and antique crimson (streaked “negoro” or texture fill, more subtle)
  • natural and black (streaked “negoro” or texture fill, very subtle)
  • or give unlimited creative license to the maker

Mekugi

  • bamboo (traditional style)
  • decorative (metal or capped style)

Kurikata Material

  • none (smooth, most common kaiken style scabbard)
  • wood (lacquered Oceanspray ironwood)
  • horn (cow or buffalo, availability/colour varies)

Measurements

Nagasa (blade length): 140-210mm
Motokasane (blade thickness): 5-7mm
Motohaba (blade width): 21-27mm
Sori (curve): uchizori
Nakago (tang): 90-100mm
Tsuka (handle): 90-100mm
Koshirae (overall): 270-350mm

Potential Raw Materials

Blade: reclaimed carriage spring steel
Habaki: reclaimed copper bus bar or fuse bar
Seppa: reclaimed copper water pipe, reclaimed brass door push plate
Handle and Scabbard: reclaimed Nootka Cypress
Kurikata: Oceanspray ironwood, reclaimed horn
Finish: natural urushi lacquer, reclaimed crushed tea leaves
Mekugi (removable peg): Bamboo

Design Your Own: Aikuchi Tanto

$3250$4050

The aikuchi tanto is characterized by the meeting of handle and scabbard and may be fully lacquered or combined with a lacquered samegawa handle.

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Description

Design a custom tanto mounted in the classical style of your choice. More info: Design Your Own Custom Tanto.

Variation shown: 8″ blade, yasurime habaki, ironwood fuchi, koiguchi, and kurikata, black matte finish, and decorative mekugi.

Island Blacksmith: Charcoal forged tanto from reclaimed files.
Island Blacksmith: Charcoal forged tanto reclaimed from farm equipment.
Island Blacksmith: Charcoal forged tanto reclaimed from files.
Island Blacksmith: Charcoal forged tanto from reclaimed steel.
Fittings: Horn Koiguchi (shown before lacquering)

Island Blacksmith: Traditional techniques and natural materials.
Fittings: Copper Koiguchi (with ring style kurikata)

Island Blacksmith: Charcoal forged tanto from reclaimed steel.
Handle: Samegawa (lacquered rayskin)

Island Blacksmith: Traditional techniques and natural materials.
Lacquer: Ishimeji (stone look, in antique crimson)

Island Blacksmith: Traditional techniques and natural materials.
Lacquer: Negoro (worn look, in natural and black)

Island Blacksmith: Traditional techniques and natural materials.
Lacquer: Matte (smooth matte look, in black)

Habaki / Blade Collar

  • yasurime (linear texture)
  • tsuchime (hammer peened texture)
  • ishimeji (stone/frosted texture)
  • or give unlimited creative license to the maker

Seppa Material

  • none (lacquer only)
  • forged copper (water pipe)
  • forged brass (door push plate)
  • or give unlimited creative license to the maker

Fuchi & Koiguchi

  • Oceanspray ironwood
  • horn (cow or buffalo, availability/colour varies)
  • or give unlimited creative license to the maker

Handle Finish

  • match scabbard lacquer
  • lacquered samegawa (various colours)
  • or give unlimited creative license to the maker

Mekugi

  • bamboo (traditional style)
  • decorative (metal or capped style)

Kurikata Material

  • wood (lacquered Oceanspray ironwood)
  • horn (cow or buffalo, availability/colour varies)
  • ring style (must be paired with a metal koiguchi)
  • or give unlimited creative license to the maker

Scabbard Finish

  • ishimeji (stone-like texture created with crushed tea leaves)
  • tsuya keshi (smooth matte surface layer)
  • negoro (“worn-look” matte surface done with two colors)
  • or give unlimited creative license to the maker

Scabbard Colour

  • natural (a red-brown when smooth, a dark chocolate when used for ishimeji)
  • black (very deep)
  • antique crimson (very deep red/brown with plum undertones)
  • black and red (streaked “negoro” or texture fill, varies greatly)
  • black and antique crimson (streaked “negoro” or texture fill, more subtle)
  • natural and black (streaked “negoro” or texture fill, very subtle)
  • or give unlimited creative license to the maker

Measurements

Nagasa (blade length): 170-240mm
Motokasane (blade thickness): 5-7mm
Motohaba (blade width): 22-28mm
Sori (curve): uchizori
Nakago (tang): 100-110mm
Tsuka (handle): 100-110mm
Koshirae (overall): 300-380mm

Potential Raw Materials

Blade: reclaimed carriage spring steel
Habaki: reclaimed copper bus bar or fuse bar
Seppa: reclaimed copper water pipe, reclaimed brass door push plate
Fuchi and Koiguchi: Oceanspray ironwood or reclaimed horn
Handle and Scabbard: reclaimed Nootka Cypress
Kurikata: Oceanspray ironwood, reclaimed horn
Handle wrap: lacquered rayskin
Finish: natural urushi lacquer, reclaimed crushed tea leaves
Mekugi (removable peg): Bamboo

Design Your Own: Hamidashi Tanto

$4100$4650

The hamidashi tanto has full mountings that may consist of twelve or more components and is characterized by a small handguard.

SKU: N/A Categories: ,

Description

Design a custom tanto mounted in the classical style of your choice. More info: Design Your Own Custom Tanto.

Variation shown: yasurime habaki, copper fuchi and kashira, iron tsuba, natural lacquered samegawa handle, and horn koiguchi.

Island Blacksmith: Charcoal forged tanto from reclaimed files.
Island Blacksmith: Charcoal forged tanto reclaimed from farm equipment.
Island Blacksmith: Charcoal forged tanto reclaimed from files.
Island Blacksmith: Charcoal forged tanto from reclaimed steel.
Handle: Gangimaki (spiral wrap)

Island Blacksmith: Charcoal forged tanto from reclaimed steel.
Handle: Samegawa (lacquered rayskin)

Island Blacksmith: Charcoal forged tanto from reclaimed steel.
Handle: Katakiri (hardwood handle)

Island Blacksmith: Charcoal forged tanto from reclaimed steel.
Fittings: Copper Fuchi (shown in progress)

Island Blacksmith: Charcoal forged tanto from reclaimed steel.
Fittings: Horn Koiguchi (shown before lacquering)

Island Blacksmith: Traditional techniques and natural materials.
Fittings: Copper Koiguchi (with ring style kurikata)

Island Blacksmith: Traditional techniques and natural materials.
Lacquer: Ishimeji (stone look, in antique crimson)

Island Blacksmith: Traditional techniques and natural materials.
Lacquer: Negoro (worn look, in natural and black)

Island Blacksmith: Traditional techniques and natural materials.
Lacquer: Matte (smooth matte look, in black)

Habaki / Blade Collar

  • yasurime (linear texture)
  • tsuchime (hammer peened texture)
  • ishimeji (stone/frosted texture)
  • or give unlimited creative license to the maker

Fuchi & Kashira

  • both copper
  • both iron
  • copper fuchi / horn kashira
  • iron fuchi / horn kashira
  • copper fuchi / hardwood kashira
  • iron fuchi / hardwood kashira
  • or give unlimited creative license to the maker

Handle Reinforcement

  • none (for hardwood handle)
  • shikagawa (deer rawhide, must be paired with gangimaki, cotton, or leather wrap)
  • samegawa (rayskin rawhide, can be lacquered, or paired with gangimaki or leather wrap)

Handle Wrap

  • gangimaki (spiral seude wrap)
  • leather lace ito (style of wrap depends on handle reinforcement)
  • lacquered samegawa (handle reinforcement must be samegawa)
  • hardwood (Sapele with fukiurushi lacquer finish)
  • lacquered cotton cord (tough and utilitarian style)
  • or give unlimited creative license to the maker

Mekugi

  • bamboo (traditional style)
  • lacquered bamboo (sealed end)
  • or give unlimited creative license to the maker

Kurikata Material

  • wood (lacquered Oceanspray ironwood)
  • horn (cow or buffalo, availability/colour varies)
  • ring style (must be paired with a metal koiguchi)
  • or give unlimited creative license to the maker

Lacquer Finish

  • ishimeji (stone-like texture created with crushed tea leaves)
  • tsuya keshi (smooth matte surface layer)
  • negoro (“worn-look” matte surface done with two colors)
  • or give unlimited creative license to the maker

Lacquer Colour

  • natural (a red-brown when smooth, a dark chocolate when used for ishimeji)
  • black (very deep)
  • antique crimson (very deep red/brown with plum undertones)
  • black and red (streaked “negoro” or texture fill, varies greatly)
  • black and antique crimson (streaked “negoro” or texture fill, more subtle)
  • natural and black (streaked “negoro” or texture fill, very subtle)
  • or give unlimited creative license to the maker

Measurements

Nagasa (blade length): 190-270mm
Motokasane (blade thickness): 5-7mm
Motohaba (blade width): 23-29mm
Sori (curve): uchizori
Nakago (tang): 100-110mm
Tsuka (handle): 100-110mm
Koshirae (overall): 320-400mm

Potential Raw Materials

Blade: reclaimed carriage spring steel
Habaki: reclaimed copper bus bar or fuse bar
Seppa: reclaimed copper water pipe, reclaimed brass door push plate
Tsuba: forged copper bus bar, fuse bar, salvaged steel, or wrought iron
Fuchi: copper bus bar, salvaged steel, or wrought iron
Kashira: Oceanspray ironwood, Wenge, reclaimed horn, copper bus bar, salvaged steel, or wrought iron
Handle core: reclaimed Nootka Cypress or Sapele
Handle reinforcement: deer rawhide, ray rawhide
Handle wrap: reclaimed suede, leather lace, lacquered rayskin
Koiguchi: reclaimed horn, copper bus bar, salvaged steel, or wrought iron
Scabbard: reclaimed Nootka Cypress
Kurikata: Oceanspray ironwood, reclaimed horn
Finish: natural urushi lacquer, reclaimed crushed tea leaves
Mekugi (removable peg): Bamboo

Design Your Own: Chisagatana Tanto

$4200$4750

The chisagatana tanto has full mountings that may consist of twelve or more components and is characterized by a large handguard.

SKU: N/A Categories: ,

Description

Design a custom tanto mounted in the classical style of your choice. More info: Design Your Own Custom Tanto.

Variation shown: yasurime habaki, brass seppa, horn kashira and kurikata, iron tsuba, leather ito wrap, black ishimeji scabbard, and copper koiguchi.

Island Blacksmith: Charcoal forged tanto from reclaimed files.
Island Blacksmith: Charcoal forged tanto reclaimed from farm equipment.
Island Blacksmith: Charcoal forged tanto reclaimed from files.
Island Blacksmith: Charcoal forged tanto from reclaimed steel.
Handle: Leather Ito (spiral wrap)

Island Blacksmith: Charcoal forged tanto from reclaimed steel.
Handle: Samegawa (lacquered rayskin)

Island Blacksmith: Charcoal forged tanto from reclaimed steel.
Handle: Katakiri (hardwood handle)

Island Blacksmith: Traditional techniques and natural materials.
Fittings: Iron Tsuba

Island Blacksmith: Charcoal forged tanto from reclaimed steel.
Fittings: Copper Fuchi

Island Blacksmith: Charcoal forged tanto from reclaimed steel.
Fittings: Horn Koiguchi

Island Blacksmith: Traditional techniques and natural materials.
Lacquer: Ishimeji (stone look, in antique crimson)

Island Blacksmith: Traditional techniques and natural materials.
Lacquer: Negoro (worn look, in natural and black)

Island Blacksmith: Traditional techniques and natural materials.
Lacquer: Matte (smooth matte look, in black)

Habaki / Blade Collar

  • yasurime (linear texture)
  • tsuchime (hammer peened texture)
  • ishimeji (stone/frosted texture)
  • or give unlimited creative license to the maker

Fuchi & Kashira

  • both copper
  • both iron
  • copper fuchi / horn kashira
  • iron fuchi / horn kashira
  • copper fuchi / hardwood kashira
  • iron fuchi / hardwood kashira
  • or give unlimited creative license to the maker

Handle Reinforcement

  • none (for hardwood handle)
  • shikagawa (deer rawhide, must be paired with gangimaki, cotton, or leather wrap)
  • samegawa (rayskin rawhide, can be lacquered, or paired with gangimaki or leather wrap)

Handle Wrap

  • gangimaki (spiral seude wrap)
  • leather lace ito (style of wrap depends on handle reinforcement)
  • lacquered samegawa (handle reinforcement must be samegawa)
  • hardwood (Sapele with fukiurushi lacquer finish)
  • lacquered cotton cord (tough and utilitarian style)
  • or give unlimited creative license to the maker

Mekugi

  • bamboo (traditional style)
  • lacquered bamboo (sealed end)
  • or give unlimited creative license to the maker

Kurikata Material

  • wood (lacquered Oceanspray ironwood)
  • horn (cow or buffalo, availability/colour varies)
  • or give unlimited creative license to the maker

Lacquer Finish

  • ishimeji (stone-like texture created with crushed tea leaves)
  • tsuya keshi (smooth matte surface layer)
  • negoro (“worn-look” matte surface done with two colors)
  • or give unlimited creative license to the maker

Lacquer Colour

  • natural (a red-brown when smooth, a dark chocolate when used for ishimeji)
  • black (very deep)
  • antique crimson (very deep red/brown with plum undertones)
  • black and red (streaked “negoro” or texture fill, varies greatly)
  • black and antique crimson (streaked “negoro” or texture fill, more subtle)
  • natural and black (streaked “negoro” or texture fill, very subtle)
  • or give unlimited creative license to the maker

Measurements

Nagasa (blade length): 220-290mm
Motokasane (blade thickness): 5-7mm
Motohaba (blade width): 24-30mm
Sori (curve): uchizori or slight sori
Nakago (tang): 100-110mm
Tsuka (handle): 100-110mm
Koshirae (overall): 350-430mm

Potential Raw Materials

Blade: reclaimed carriage spring steel
Habaki: reclaimed copper bus bar or fuse bar
Seppa: reclaimed copper water pipe, reclaimed brass door push plate
Tsuba: forged copper bus bar, fuse bar, salvaged steel, or wrought iron
Fuchi: copper bus bar, salvaged steel, or wrought iron
Kashira: Oceanspray ironwood, Wenge, reclaimed horn, copper bus bar, salvaged steel, or wrought iron
Handle core: reclaimed Nootka Cypress or Sapele
Handle reinforcement: deer rawhide, ray rawhide
Handle wrap: reclaimed suede, leather lace, lacquered rayskin
Koiguchi: reclaimed horn, copper bus bar, salvaged steel, or wrought iron
Scabbard: reclaimed Nootka Cypress
Kurikata: Oceanspray ironwood, reclaimed horn
Finish: natural urushi lacquer, reclaimed crushed tea leaves
Mekugi (removable peg): Bamboo


Constructed in the style of a traditional Japanese sword, only a single bamboo peg is required to hold the knife together. This beautifully simple design allows the tanto to be taken apart for cleaning, polishing, or repair work.


Behind the Scenes

Crossed Heart Forge: Design your own tanto, hand crafted in Canada.
hand made charcoal
Tools for Satoyama: Design your own knife, hand crafted on Vancouver Island.
hand forged steel
Island Blacksmith: Design your own charcoal forged tanto made from reclaimed steel.
hand carved wood


My approach as a craftsman is to work within the creative constraints of the classical tanto form and nihonto handle mounting technology, building on a foundation of Japanese swordsmithing aesthetic and technique.”


How Tanto Are Made

Island Blacksmith: Hand forged tanto reclaimed from carriage springs.
Historical Techniques
Island Blacksmith: Hand crafted tanto from natural materials.
Traditional Tools
Island Blacksmith: Charcoal forged tanto from reclaimed steel.
Reclaimed Materials


Traditionally crafted tanto for people who wish they could take things home from museums. Charcoal forged classical heirloom tanto made by hand from reclaimed and natural materials using 13th century techniques.

Making Charcoal from Scrap Wood

Island Blacksmith: Charcoal forged tanto, reclaimed steel.
The best forge fuel for high carbon steel tanto is softwood charcoal. The raw material is scrap wood from local sources such as furniture makers, carvers, and foresters.

Island Blacksmith: Charcoal forged tanto, reclaimed steel.
The charcoal kiln is loaded, the door is put in place, the fire is tended for several hours until the steamy smoke changes colour, and then it is completely sealed until it cools down.

Island Blacksmith: Charcoal forged knives reclaimed from harrow teeth.
After completely cooling the kiln is opened and the charcoal can be chopped and sorted into grades of bladesmithing charcoal and heat treating charcoal. (Watch .)

Finding the Raw Materials

Island Blacksmith: Charcoal forged tanto, reclaimed steel.
The blade steel is mainly curated from old homestead piles, this one formerly belonging to a blacksmith and farmer. Old farm equipment and carriage spring steel make great blades.

Island Blacksmith: Charcoal forged knives reclaimed from harrow teeth.
Potential blade steels are tested using several methods to determine their suitability and the best approach for heat treatment. The older, lower alloy steels are preferred by our inspectors.

Island Blacksmith: Charcoal forged tanto, reclaimed steel.
Carbon steel takes and holds a great edge and responds well to traditional water and clay yaki-ire hardening. These carriage springs may be well over a century old. (Watch .)

Forging the Blade from Reclaimed Steel

Island Blacksmith: Charcoal forged tanto, reclaimed steel.
The elemental simplicity of a brick charcoal forge supplied with air from a hand powered wooden fuigo box bellows forms the starting place for the shaping of a blade.

Island Blacksmith: Charcoal forged tanto, reclaimed steel.
Most of the shaping can be done with well-placed blows from a hand hammer. Accurate forging makes the quickest and most efficient use of an entire piece of reclaimed steel.

Island Blacksmith: Charcoal forged knives reclaimed from harrow teeth.
A well forged piece is very close to its final size and saves time and waste when hand filing to final shape. A sen scraper and files are used to refine and true the form. (Watch some .)

Hardening & Tempering the Blade

Island Blacksmith: Charcoal forged tanto, reclaimed steel.
The traditional yaki-ire hardening method using natural clay, charcoal, and rainwater can be risky but produces a hard cutting edge and a tough spine within a single piece of carbon steel.

Island Blacksmith: Charcoal forged knives reclaimed from harrow teeth.
After the clay layer has dried, the blade is slowly heated to the colour of the august moon and then plunged into water. The exposed edge cools more quickly and forms a very hard steel structure.

Island Blacksmith: Charcoal forged tanto, reclaimed steel.
The body and spine of the blade cool more slowly and form a very tough steel structure. The rough stone finish on this blade reveals the temper line between the two areas. (Watch .)

Making the Fittings

Island Blacksmith: Charcoal forged tanto, reclaimed steel.
Reclaimed copper from electrical bus bars is very pure and forges well. Other materials include wrought iron salvaged from the sea, reclaimed brass door plate, and scrap copper water pipe.

Island Blacksmith: Charcoal forged tanto, reclaimed steel.
Because the entire knife is held together with a single bamboo peg in the style of classical tanto, each metal and wood component must fit accurately on the tang of the blade.

Island Blacksmith: Charcoal forged tanto, reclaimed steel.
The copper components are allowed to develop a fire patina or given a traditional rokusho style patina and then finished with buffed ibota wax or tung nut oil. (Watch .)

Making the Handle & Scabbard

Island Blacksmith: Charcoal forged tanto, reclaimed steel.
The inside of handle and scabbard must fit the tang and blade precisely before the halves can be joined together with sokui (rice paste glue). (Learn about sokui.)

Island Blacksmith: Charcoal forged tanto, reclaimed steel.
Once the halves are rejoined, shaping and finishing the exterior of the Hounoki core is done with Japanese hand saws, planes, chisels, rasps, and kiridashi knives.

Island Blacksmith: Charcoal forged tanto, reclaimed steel.
Each component is carefully carved, shaped, and fit together to provide strength and make best use of the natural properties of each material. (Watch a tanto mounting being .)

Lacquering with Natural Tree Urushi

Island Blacksmith: Charcoal forged tanto, reclaimed steel.
The first layers of urushi lacquer are applied thinly and wiped off to seal the wood until fully cured. Each layer is cured for several days and then polished before the next is applied.

Island Blacksmith: Charcoal forged knives reclaimed from harrow teeth.
For an ishimeji stone finish, crushed dried tea leaves are sprinkled into the wet urushi. After curing for several days, the tea leaves are sealed and strengthened with more lacquer.

Island Blacksmith: Charcoal forged tanto, reclaimed steel.
Once the lacquer has fully cured, the fixed components are attached using kusune (pine resin glue) or a mixture of urushi and sokui, called nori-urushi. (Watch a tanto being .)

Final Assembly

Island Blacksmith: Charcoal forged tanto, reclaimed steel.
A full tanto mounting may contain ten or more parts made from twenty or more components. Most of the parts are fit together only by friction and locked in place by the bamboo peg.

Island Blacksmith: Charcoal forged tanto, reclaimed steel.
The major components of handle and scabbard are assembled. A combination of wood, rawhide, and tightly wrapped leather or cord strengthens the handle assembly.

Island Blacksmith: Charcoal forged tanto, reclaimed steel.
Once all of the fittings have been built, the blade is given its final polish using fine natural Japanese waterstones and finger stones. (Watch a tanto being .)


Create An Heirloom



Are these tanto custom made to order?
Yes! When your payment is received the project will begin, each tanto is made to order, one at a time, by hand from reclaimed and natural materials.

Are they really made by hand?
In every sense of the word. There is no waterjetting, no belt grinder or buffing wheel, no power hammer, and no fossil fuels involved. From the time the steel is first placed in the fire to the final assembly, they are crafted with human hands and centuries-old techniques.

How long will it take to complete my tanto?
Projects will be started in the order they arrive and completion time is generally about three months, but it can vary quite a bit. If you have a specific time goal you would like to aim for, please plan ahead accordingly and include your request as an order note.

Why does it take so long to handcraft my tanto?
Actual hand working time is usually between 100 and 150 hours for a full mounting but there needs to be cooling/drying/curing time between each stage. By far the lacquer takes the most wait time and different types of urushi finishes and even the season of year will greatly affect the rate of curing.

Can I take my tanto apart?
All of the components (blade, guard, fittings, and handle) are fit snugly and held together by the mekugi peg, removing the peg allows the tanto to be taken apart for sharpening and cleaning. Reassembly should be done with utmost attention to the position of each piece, even the mekugi peg needs to be rotated to the correct position before insertion.

More importantly, can I put it back together again?
The mekugi peg is designed to fit in only one position, check for the unbroken lines on the bamboo or the three lines filed in the hardwood peg and turn them towards the pommel (back of the handle). Make sure that the blade, guard, and other fittings are fully seated in their original positions before pressing the mekugi in place.

How accurate are the measurements given for each tanto?
Due to the handmade and unique nature of the tanto they are each different and may vary noticeably in measurement or style. Rarely are blades much shorter but if the steel is there they may go longer. If you have a specific measurement requirement (eg. a legal limit), please include your request as an order note.

Can I get more specific about certain finish and colour requests?
Want to select the option, “get creative” but don’t want any red, for example? If you have a specific idea, please include your request as an order note.

Can I send you my own legacy raw materials?
Want to use an old file from grandpa’s toolbox as your blade material? Have grandma’s silver spoon forged into a guard or seppa? This type of request is often possible, please include your request as an order note.

What about extra upgrades not listed in the options?
In certain cases it may be possible to upgrade to include options that are not listed above. If would like upgrade pricing information (eg. a raw material or component not listed), please include your request as an order note.

Is there some care and maintenance information available?
In a nutshell: keep them clean and dry. More detailed information can be found here: Knife Use & Care

How do the “Tools for Satoyama” tanto differ from the classical tanto?
The core quality and process is the same for both, but three main differences that contribute to the 100-150 hours labour for a classical tanto are the size (larger blades take more time and resources), the number of components and fittings (fully mounted tanto can have 12 or more parts), and the finish of each part (polishing the blade and fittings, complex urushi finishes and handle wrappings).

Are there more detailed terms and conditions for ordering?
More details and the standard terms for ordering tanto can be found here: Terms & Conditions


Get in Touch

Want to order a smaller satoyama style kotanto instead? Do it here. More questions? Please contact info@islandblacksmith.ca

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