For those of you follow the instagram page, you may have noticed I've been teasing a project for some time now. Finally ready to reveal the results!
Awhile back Ryan (
@Illyria) and I were sharing some (or a lot) virtual beers and just generally chatting knives, polishing, etc. At some point while discussing wrought iron, I had a rare moment of genius and asked if he could use old, clapped out kanna blades to create a damascus cladding. Ryan graciously agreed and by morning I'd purchased dozens of worn out blades and had them on the way to
New Mexico prefecture. Additionally, I sourced Aogami #1 for him to use as well.
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Next the hard work began. Ryan needed to clean off the rust and sort the kanna. Then each was forged into a consistent size before creating cladding billets using 6-8 kanna each.
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The result was a high layer damascus with multiple wrought irons and steels (white, blue, and even one tamahagane one slipped into the mix). Not only does this create a visually pleasing pattern, but it is immensely satisfying to give these worn out tools new life. Additionally tools are typically made from rather high quality iron and steel so the overall material quality in the billet was high as well. For this first round of knives Ryan made two variants, a twist and then a higher layer random stack.
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Ryan then forged out the knives and appleid a modern HT with multiple rounds of thermal cycling, cryo-treatment, and other voodoo that is well over my head to yield something quite astounding from the Aogami 1 - a core hardness of 66.6! You may think this would be unreasonably chippy or otherwise fragile, but I've sharpened and used my example extensively now and am pleased to report no such issues! The worst I can say about this is that the steel sharpens and polishes exactly as slowly as you'd expect an extremely hard steel would.
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Some of the kanna blades ended up coming with a dai as well, so we elected to continue the reclaimed theme and use the oak from the dai to create the handles as well. Japanese dai oak is of extremely high quality with a dense, consistent grain structure. Wood for dye blocks is traditionally aged for years, usually a decade or more and is therefore extremely stable. The wood ended up having exceptional grain and wonderful warmth in the hand after it got cleaned up.
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I am still working on the stone polish for my personal example, but it's too good not to share Ryan's pictures.
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Coming up, I'll share more about the twisted & deep etched clad version that will be available on the shop.