Design Your Own Knife: Tools for Satoyama


Tools for Satoyama: Choose a blade, hand crafted on Vancouver Island.

Step 1 – choose a blade

charcoal forged and clay tempered.


Tools for Satoyama: Design a knife, hand crafted on Vancouver Island.

Step 2 – design your knife

hand crafted from natural materials.


Tools for Satoyama: Design a knife, hand crafted on Vancouver Island.

Step 3 – adventure awaits

the journey and the destination.


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.

Choose a Blade


The water and clay hardening process historically developed for Japanese swords allows the temper of the high carbon steel to remain quite hard and is preferred by those who require a keen edge and are willing to take care of it.


Design Your Knife


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

Design Your Own: Stream Kotanto

$700$900

The narrower blade profile of the compact stream style kotanto is based on a classical yoroidoshi tanto and has a gradual drop point for detailed work.

SKU: N/A Categories: , Tags: , ,

Description

Design a custom kotanto blade mounted in the rustic satoyama kaiken style of your choice. More info: Design Your Own Custom Knife.

Variation shown: hammer finish blade, brass seppa, natural lacquered handle and scabbard, and bamboo mekugi.

Island Blacksmith: Charcoal forged knives reclaimed from files.
Island Blacksmith: Charcoal forged knives reclaimed from farm equipment.
Island Blacksmith: Charcoal forged knives reclaimed from harrow teeth.
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)

Mekugi

  • bamboo retaining peg (the classic)
  • dark hardwood peg (black or brown wood like Walnut, Wenge)
  • light hardwood peg (red or orange wood like Sapele, Yew, Oceanspray)

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)
  • or some combination (including giving unlimited creative license to the maker)

Lacquer Colour

  • natural (a red-brown colour when used for fukiurushi, a dark chocolate brown 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): 50-80mm
Motokasane (blade thickness): 3-5mm
Motohaba (blade width): 18-22mm
Sori (curve): uchizori
Nakago (tang): 70-80mm
Tsuka (handle): 90-100mm
Koshirae (overall): 150-190mm

Potential Raw Materials

Blade: reclaimed file steel, reclaimed harrow tooth steel
Seppa (guard): forged copper washer, brass door plate, 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, hardwood

Design Your Own: Field Kotanto

$825$1050

The wider blade profile of the field style kotanto is inspired by a classical sword and has a more deeply curved belly (fukura-tsuku) and shorter drop point.

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Description

Design a custom kotanto blade mounted in the rustic satoyama kaiken style of your choice. More info: Design Your Own Custom Bushcraft Knife.

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

Island Blacksmith: Charcoal forged knives reclaimed from files.
Island Blacksmith: Charcoal forged knives reclaimed from farm equipment.
Island Blacksmith: Charcoal forged knives reclaimed from harrow teeth.
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)

Guard Style

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

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)
  • or some combination (including giving unlimited creative license to the maker)

Lacquer Colour

  • natural (a red-brown colour when used for fukiurushi, a dark chocolate brown 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): 70-100mm
Motokasane (blade thickness): 4-6mm
Motohaba (blade width): 24-28mm
Sori (curve): uchizori
Nakago (tang): 80-90mm
Tsuka (handle): 100-110mm
Koshirae (overall): 190-230mm

Potential Raw Materials

Blade: reclaimed file steel, harrow tooth steel
Tsuba (guard): forged copper bus bar, 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, hardwood

Design Your Own: Forest Kotanto

$875$1450

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

SKU: N/A Categories: , Tags: , ,

Description

Design a custom kotanto blade mounted in the rustic satoyama kaiken style of your choice. More info: Design Your Own Custom Outdoor Knife.

Variation shown: hammer finish blade, copper seppa, and natural brown ishimeji lacquer on handle and scabbard.

Island Blacksmith: Charcoal forged knives from reclaimed files.
Island Blacksmith: Charcoal forged knives from reclaimed farm equipment.
Island Blacksmith: Charcoal forged knives reclaimed from harrow teeth.
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.
Negoro (two colour “worn” fukiurushi) in natural and black

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)

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 colour when used for fukiurushi, a dark chocolate brown 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)

Approximate Measurements

Nagasa (blade length): 100-130mm
Motokasane (blade thickness): 4-6mm
Motohaba (blade width): 22-26mm
Sori (curve): uchizori/takenoko
Nakago (tang): 90-100mm
Tsuka (handle): 100-110mm
Koshirae (overall): 220-260mm

Potential Raw Materials

Blade: reclaimed file steel, harrow tooth steel
Seppa (guard): forged copper washer, brass door plate, 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, hardwood

Design Your Own: Mountain Kotanto

$975$1600

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

SKU: N/A Categories: , Tags: , ,

Description

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

Variation shown: hammer finish blade w/o habaki, copper hamidashi guard, natural brown fukiurushi cord wrap handle, and natural brown ishimeji lacquered scabbard.

Island Blacksmith: Charcoal forged knives reclaimed from files.
Island Blacksmith: Charcoal forged knives reclaimed from farm equipment.
Island Blacksmith: Charcoal forged knives reclaimed from harrow teeth.
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

  • with habaki (blade collar, helps hold in the scabbard)
  • without habaki

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 colour when used for fukiurushi, a dark chocolate brown 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): 130-150mm
Motokasane (blade thickness): 5-7mm
Motohaba (blade width): 28-32mm
Sori (curve): uchizori
Nakago (tang): 90-100mm
Tsuka (handle): 100-120mm
Koshirae (overall): 250-290mm

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, 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


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 the Knives 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 knives for people who wish they could take things home from museums. Charcoal forged classical tanto & fusion style heirlooms 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 knives reclaimed from files.
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 knives reclaimed from files.
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. This also allows for the fire finish to remain on the blade. (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 knives reclaimed from files.
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 knives reclaimed from files.
Reclaimed copper from electrical bus bars is very pure and forges well. Other materials include wrought iron salvaged from the sea and forged into guards and seppa washers.

Island Blacksmith: Charcoal forged knives reclaimed from files.
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 knives reclaimed from files.
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 knives reclaimed from files.
Shaping and finishing of the Nootka Cypress is based on the classical forms and is done with Japanese hand saws, planes, chisels, and kiridashi knives.

Island Blacksmith: Charcoal forged knives reclaimed from files.
The hand carved surface of the “Tools for Satoyama” style has facets that are highlighted by the fukiurushi lacquering technique. (Watch a kotanto mounting being .)

Lacquering with Natural Tree Urushi

Island Blacksmith: Charcoal forged knives reclaimed from files.
The first layers of urushi lacquer are applied thinly and wiped off to seal the wood until fully cured. Then cotton or hemp cord is tied, stretched tightly, and saturated with urushi.

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 and cord are sealed and strengthened with lacquer.

Island Blacksmith: Charcoal forged knives reclaimed from files.
After several final layers of lacquer have fully cured, the blade is given its final edge using waterstones and the knife is ready to assemble. (Watch a kotanto being .)


Adventure Awaits



Are these knives custom made to order?
Yes! When your payment is received the project will begin, each knife 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, “Tools for Satoyama” are crafted by human hands and centuries-old techniques.

How long will it take to complete my knife?
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 knife?
Actual hand working time is usually between 20 and 50 hours 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 knife apart?
All of the components (blade, guard, and handle) are fit snugly and held together by the mekugi peg, removing the peg allows the knife to be taken apart for sharpening and cleaning. Lightly tapping a soft wood mallet against the front of the guard on each side will help when stuck.

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 and guard are fully seated in their original positions before pressing the mekugi in place.

How accurate are the measurements given for each knife?
Due to the handmade and unique nature of the knives 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? 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 wooden kurikata, a leather wrapped handle, a habaki, or a more refined lacquering style), please include your request as an order note.

Is there some care and maintenance information available?
In a nutshell: use carbon steel knives for tasks they were designed for and keep them sharp, clean, and dry. More detailed information can be found here: Knife Use & Care

How is this process different from a normal custom knife order?
This webpage for the “Tools for Satoyama” project aims to create a simpler and more time/cost effective way for clients to personally design and order a handmade custom knife. The grouped options and minimal components help to streamline the decision making process.

How do the “Tools for Satoyama” knives differ from a custom 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 knives can be found here: Terms & Conditions


Get in Touch

Want to order a full sized satoyama style tanto or a custom classical tanto instead? Do it here. More questions? Please contact info@islandblacksmith.ca

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