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View Full Version : Custom gyuto by Ian Rogers - the process



Matus
03-11-2014, 03:36 PM
I was on a search for a 240mm mid-price gyuto and after lengthy discussion the name Haburn knives was mentioned. Ian Rogers is the maker. Ian recently became Vendor here on KFF. After seeing his knives I dropped him an email and asked about pricing and waiting time. Both answer got me by surprise (no waiting time at that point and very reasonable price) - so I decided to pull a trigger on my first custom knife.

I thought I could share the "story" here and so here it comes.

Before I start I think it would make sense to mention the objectives. The outcome should be:
- 240mm gyuto in AEB-L steel
- the knife should be "stronger" than a laser and should not have too much flex.
- The blade should not be taller than 50mm - in fact it will probably be a little less.
- The handle will be based on some of Ian's designs. Details are not set yet.

The process started with Ian making a blade profile proposal. So far there have been 3 and if I will not change my mind it will be the third one.

So - the designs (to scale relative to each other) - currently it is the bottom one that should be made. The height at the heel is 47mm on all of these. The tip on the bottom 2 designs has the same position relative to the heel and is ca 22mm from the spine axis:

http://farm3.staticflickr.com/2272/13089150505_34fd55fb49_z.jpg (http://www.flickr.com/photos/31007239@N06/13089150505/)

Please do not hesitate to share your opinion :)

EDIT: The belly of the blades continues up to the tip (I asked Ian) - it just looks a little flat in the tip on in the image. I checked it with Photoshop :)

Ucmd
03-11-2014, 10:21 PM
I would choose the bottom profile.

Lefty
03-11-2014, 10:32 PM
Tough choice. I like the top and bottom, myself.

Hbeernink
03-11-2014, 11:48 PM
Tough choice. I like the top and bottom, myself.

my thoughts exactly - #1 and #3 both look great. too much belly in #2, I think. I like the shape of the choil - similar to teruyasu fujiwara's shape - I always thought that was a neat addition.

I've found at 240-270mm I prefer a tip that drops a bit more (e.g. similar to the first profile), and this is very similar to the gesshin hinoura/ajikataya line at JKI. for me, it's a better feel when using the tip for detail work (where I use my index finger on the spine, rather than a pinch grip).

that said, I also really like the masamoto gyuto profile - which looks like the third one. Great all-around profile for me, and while I don't use my masamoto as much as some other gyutos, everytime I do I'm asking myself why I don't use it more often....

Matus
03-14-2014, 02:34 AM
Glad to see you guys like the profile.

Here is a little update - choosing the design and material is tougher task that I though. While the design is still in works, the material was already chosen. So if everything goes fine this beautiful piece of Oregon Maple burl should be the main handle material:

http://farm4.staticflickr.com/3690/13141487653_e0b2cc2fe7_c.jpg

daddy yo yo
03-14-2014, 03:23 AM
I would choose the bottom profile, no. 3 that is...

Nice piece of handle wood!

Curious to see more!

Bill13
03-14-2014, 05:38 AM
I like 3 the most followed by 1 and then 2. Really like the wood. Not sure I like the pointed handle end.

WildBoar
03-14-2014, 11:17 AM
agree -- 3>1>2. Well actually I would not want 2, but could live with 1.

Matus
03-14-2014, 06:01 PM
So - most important design decisions were taken. In some 5-6 weeks the knife could be ready to be shipped :knife:

Keep an eye on this thread - Ian will keep posting updates on the progress here :)

erikz
03-14-2014, 06:38 PM
3>2>1

Looking forward to the final product Matus!

Mangelwurzel
03-25-2014, 06:00 AM
Glad to see you guys like the profile.

Here is a little update - choosing the design and material is tougher task that I though. While the design is still in works, the material was already chosen. So if everything goes fine this beautiful piece of Oregon Maple burl should be the main handle material:

http://farm4.staticflickr.com/3690/13141487653_e0b2cc2fe7_c.jpg

Hey Matus, did Ian recommend that wood to you or did you have to source it yourself?

Matus
03-25-2014, 11:32 AM
Ian recommended me the vendors (both are also vendors here on KKF). We then discussed what type of wood would fit the knife and what size will be necessary. That piece above is indeed on the larger side, but I just liked the structure & color.

So - I chose the wood, but Ian then ordered it directly from the shop. Had I sourced the wood elsewhere it would have been OK too - I just did not have the need (or means) to do so. It would also have been an unnecessary complication because I am located on different continent than Ian :)

Haburn
03-28-2014, 05:48 PM
Here I'm working on the shoulder. I'm using a diy guide to make sure the shoulder will be straight and flush when it meets up with the bolster.

http://i.imgur.com/6KoTJFvl.jpg

Matus
03-29-2014, 12:15 PM
Woo-hoo! Here we come :bliss:

Now I just need to sit back and enjoy :popcorn:

Haburn
04-03-2014, 03:01 PM
MMM...Blade is hand finished.

http://i.imgur.com/Tc3zbeHl.jpg

Milling the bolster slot.

http://i.imgur.com/hPpAeHRl.jpg

Oregon maple burl from Burlsource.

http://i.imgur.com/XJCG4CXl.jpg

Matus
04-03-2014, 05:11 PM
Ian - you have made quite a progress. What will come next?

Haburn
04-03-2014, 05:57 PM
Ian - you have made quite a progress. What will come next?
A cup of coffee and biscotti. Seriously. That. :hungry:
On the knife, I'll be attaching the bolster. Pics to come.

Matus
04-04-2014, 12:37 AM
Sounds good. I'll have a cappuccino, "butterbezel" and a "quarktasche" as soon as our cafeteria will be opened at 8'clock. Sadly - it is still just 6:30 :coffeelove:

daddy yo yo
04-04-2014, 05:44 AM
"Koane Weisswiascht"???

Matus
04-04-2014, 05:52 AM
"Koane Weisswiascht"???

Hat to google that as I am not German, but no, no weisswurst at work, just the butterbrezel (I love them) :)

Haburn
04-04-2014, 02:57 PM
All this food talk is making me hungry.

Here is the bolster after some shaping.
http://i.imgur.com/JuPVGcEl.jpg

More shaping and hand sanding.
http://i.imgur.com/vDHp4Kyl.jpg

If I fits, I sits.
http://i.imgur.com/tonWPHml.jpg

Matus
04-04-2014, 05:27 PM
Ian, that bolster looks great.

Matus
04-07-2014, 01:21 AM
I have just got an email from Ian, you know, THAT one :happy1: Expect some photos soon! :lol2:

Haburn
04-07-2014, 01:50 AM
Finished product:

http://i.imgur.com/mosEzWzl.jpg

http://i.imgur.com/dhzAiQ2l.jpg

http://i.imgur.com/JViSOyFl.jpg

http://i.imgur.com/OHoLFDPl.jpg

http://i.imgur.com/i9rCuKdl.jpg

http://i.imgur.com/cOp05Hal.jpg

chefcomesback
04-07-2014, 01:54 AM
Looks great Ian

rami_m
04-07-2014, 01:57 AM
What handle style is that?

rami_m
04-07-2014, 02:08 AM
You know, I really like Ian's style. It's one of the things that attracted me in the first place. Hope to see mine soon :). Let me know how it preforms.

Matus
04-07-2014, 02:17 AM
What handle style is that?

It is hidden tang octagonal handle - taller than wider. Full tang would have required (according to Ian) slightly taller blade and made the knife more butt heavy (the second is my guess)

Once I have it in my hands I will definitely make a review and share it here.

@Ian - where is actually the center of mass of the knife?

erikz
04-07-2014, 02:20 AM
Thats a beauty Ian!

This is going to be so much fun to use Matus, you probably can't wait to get your hands on it :)

Haburn
04-07-2014, 02:22 AM
It is hidden tang octagonal handle - taller than wider. Full tang would have required (according to Ian) slightly taller blade and made the knife more butt heavy (the second is my guess)

Once I have it in my hands I will definitely make a review and share it here.

@Ian - where is actually the center of mass of the knife?

Balance is between the "R" and the "N" on the logo. Weight is ~244 grams.

rami_m
04-07-2014, 02:24 AM
I noticed that the final handle is a bit darker than the burl picture. Is that intentional?

Haburn
04-07-2014, 10:21 AM
I noticed that the final handle is a bit darker than the burl picture. Is that intentional?
The photos of the wood block are taken without a light box. The knife photos are inside a light box, which diffuses the light to spread it more evenly across the knife. There isn't any bright light inside the light box which is probably the difference that you are seeing. The leftover wood and the handle are the same color. :)

Burl Source
04-07-2014, 10:28 PM
Beautiful Knife Ian.
Will you be at the Eugene knife show this weekend?

Haburn
04-08-2014, 12:03 AM
Thanks Mark. I won't be at the show this weekend.

daddy yo yo
04-08-2014, 08:32 AM
I like both the knife and the photography!

Matus
04-08-2014, 04:41 PM
I like both the knife and the photography!

me too :D

Matus
04-12-2014, 05:27 PM
According to USPS the knife arrived to customs today. Jest few km away. I can feel its presence :ninja:

:)

Haburn
04-12-2014, 08:05 PM
Oh ya!

Mangelwurzel
04-14-2014, 04:54 AM
Congrats on the score, Matus! It's a beautiful knife. Looking forward to reading your review.

Bill13
04-14-2014, 09:46 AM
Love the profile, and the handle is a work of art! Nicely done.

Matus
04-15-2014, 03:44 PM
Since I have not heard from the customs yet, it seems like I will only be able to get my hands on the knife after Easter :sad0:

erikz
04-15-2014, 03:49 PM
Thats too bad Matus. Enjoy easter and hopefully your knife arrives very soon!

rami_m
04-15-2014, 05:01 PM
It's only a couple if days. Hope you get it soon.

Haburn
04-15-2014, 08:39 PM
Since I have not heard from the customs yet, it seems like I will only be able to get my hands on the knife after Easter :sad0:
AHHH....get it together already, Customs. :nunchucks:

Matus
04-16-2014, 01:36 AM
AHHH....get it together already, Customs. :nunchucks:

Yeah, I keep starring at the USPS tracking page and waiting for "Recipient is being notified" :bashhead:

And now even the USPS webpage is temporarily not working :angryspin:

I need to take more relaxed stance I guess :wink:

Matus
04-23-2014, 04:28 AM
This becoming a patience lessen for me ... :sad0:

erikz
04-23-2014, 04:49 AM
This becoming a patience lessen for me ... :sad0:
Wow, this really is taking ages. I thought German customs was better compared to Dutch customs (they really really suck), but they're starting to trump the Dutchies...

Good luck waiting man!

berko
04-23-2014, 04:50 AM
german custom guys are not the fastest... ive been there yesterday to pick up some tojiros for my apprentice: one guy workin, 4 guys lookin around...

erikz
04-23-2014, 04:52 AM
german custom guys are not the fastest... ive been there yesterday to pick up some tojiros for my apprentice: one guy workin, 4 guys lookin around...
Seems like a dream job, do they have any positions that need to be filled? :p

Matus
04-23-2014, 05:21 AM
Yeah, the guys working there do not seem too stressed. In my case there was Easter in between and I also do not know how long it takes for the goods to get from Frankfurt to Aalen customs. When I called them last Wednesday the package was not in Aalen yet even though it was already in Germany. I do hope to get the knife in the course of this week.

Wish me luck :)

erikz
04-23-2014, 05:33 AM
Good luck man :)

Matus
04-24-2014, 04:39 PM
And here it comes! I have picked up the knife just few hours ago. After unpacking I could only say ... "wow" ... I mean - I do not use that word much, but my jaw just dropped :excited:

I am not going into too many details at this point - just let me mention that .. :
... the F&F of the blade and handle is amazing.
... the design of the knife is great and looks even better live than in pictures.
... the knife has quite some heft (shy under 250g).
... the blade is shaving sharp and push cuts paper like it was made for it.
... the handle feels great in hand.
... I am out of words from joy!

@Ian - thank you, thank you very much, you did some really great work on this one! :thumbsup:

I had to take photos, of course :), but now let me share just one (the light was already fading outside). I will make a full review once I get to use the knife - then more photos will come.

If there are any questions about the knife - just post them here and I will answer them in the review. Otherwise my PM box will explode :)

https://farm6.staticflickr.com/5087/13999388654_7fb2fc6bf3_b.jpg (https://www.flickr.com/photos/31007239@N06/13999388654/)

WarrenB
04-24-2014, 05:48 PM
Beautiful knife, congrats to the owner and maker:doublethumbsup:

Lefty
04-24-2014, 06:34 PM
Wow. Pretty spectacular looking piece!

Haburn
04-24-2014, 10:57 PM
Glad you FINALLY got it through customs and you are happy with it.
That cutting board is niiiiiice.

Matus
04-25-2014, 01:35 AM
Thanks guys. I will make a short write-up on the board as well once I find the time. It is awesome indeed :)

ramenlegend
04-25-2014, 02:19 AM
daaaaannnggg! I can't wait to hear about this thing. I got a feeling that Ian's site is going to explode :D

icanhaschzbrgr
04-25-2014, 02:36 AM
Looks great! Congratulations Matus :thumbsup:

erikz
04-25-2014, 03:01 AM
Wow man, I love the look of that ferrule with the spacer and the contrast with the rest of the handle. Enjoy Matus :) I'm sure you will!!!

Mucho Bocho
04-29-2014, 09:40 AM
Matus, We're looking forward to your feedback on this Haburn Custom Gyuto. I've got to believe you've made a few cuts by now. What say you Man?

Matus
04-29-2014, 09:58 AM
Since you guys insist - the knife slices meat like a dream. It does seem a bit too thick behind the edge for carrots or potatoes and the like (to make it clear - it was ordered as workhorse that should not flex too much) - but I need to use it more to see whether thinning will be done or not.

Frankly I still need to make some more meat work to be able to tell you more, but it sits great in hand and thanks to its weight it glides through the meat with no effort.

Matus
05-01-2014, 12:45 PM
I know that half of KKF is waiting for the review (or so I keep telling myself :) ), but the knife will first go bak to Ian so that he can make some adjustments (thinning). On the way back it will be accompanied by a pairing knife from Ian (that is meant for my wife) - I will then review them both together.

It is not easy for me to part with the gyuto even if only for a few weeks. It is just so nice :)

XooMG
05-01-2014, 02:33 PM
Glad you like it. I was on the edge of an order but decided to hold off for a while. I'm a fan of paper-thin edges personally so workhorse reviews don't do much for me, but it'll still be interesting to read.

Matus
05-01-2014, 03:03 PM
Just to make it clear - the 'workhorse' feature was my request (and admittedly something I should have defined more clearly) - I do not think that that is something Ian does by default. And surely he has no problem to make knifes that are thin behind the edge (would be a tough business for him otherwise I guess). Just drop him en email if you have questions.

Mangelwurzel
06-19-2014, 11:42 AM
I know that half of KKF is waiting for the review (or so I keep telling myself :) ), but the knife will first go bak to Ian so that he can make some adjustments (thinning). On the way back it will be accompanied by a pairing knife from Ian (that is meant for my wife) - I will then review them both together.

Hey Matus, have you received your gyuto back from Ian get? I think you've still got half of KKF waiting for the review ;)

Matus
06-19-2014, 11:54 AM
I am in frequent contact with Ian. The gyuto was thinned and refinished, but is still at Ian's shop for a very simpler reason - he is doing 100mm pairing knife for my wife and so I have decided to wait until the parer will be ready so save a bit on shipping.

I promisse - the review will come.

Haburn
08-21-2014, 08:14 PM
Gyuto and matching paring, plus flowery mosaic pin for Mrs. Matus.

http://i.imgur.com/xMiUcOLl.jpg

Choil shot of the gyuto. For the numbers folks:
Behind the edge is .005in/.14mm
.5in/12mm behind the edge is .03in/.8mm

http://i.imgur.com/7ZRhwNsl.jpg

marc4pt0
08-21-2014, 08:32 PM
Holy sugar snap peas! Very thin!
What's the spine measurement again?

Mrmnms
08-21-2014, 08:32 PM
Gyuto and matching paring, plus flowery mosaic pin for Mrs. Matus.

http://i.imgur.com/xMiUcOLl.jpg

Choil shot of the gyuto. For the numbers folks:
Behind the edge is .005in/.14mm
.5in/12mm behind the edge is .03in/.8mm

http://i.imgur.com/7ZRhwNsl.jpg

They both look fantastic .

Haburn
08-21-2014, 08:46 PM
Holy sugar snap peas! Very thin!
What's the spine measurement again?

Above the heel: .11in/2.8mm
Midway: .1in/2.5mm
~1in/25mm from the tip is .03in/.8mm

Matus
08-22-2014, 12:48 AM
Ian, just awesome, thank you :thumbsup:

But now I have to wait to mid September (because of vacation and shipping times to Europe) to get my hands on them - long 4 weeks of wait.

And yes - the long promised review will come afterwards - with a little surprise :groucho: :biggrin:

jsjs103121
08-22-2014, 03:06 AM
Looks amazing Ian. :doublethumbsup:

CutFingers
08-22-2014, 05:02 AM
That looks awesome. The handle contour and design looks ergonomic from the picture. Pretty light weight blade wow. Nice.

Matus
09-23-2014, 02:54 PM
The knives have arrived! The gyuto lost 30g (!) in the thinning process. It is too early to try to get into details - the knife will now get used as much as possible and the promised review WILL come in few weeks time :)

Yes, they both look gorgeous - the pairing knife is a little jewel :)

Thank you Ian!