In this is a 3-day course you will be taken through the full process of forging 100 layered Damascus steel billet and transforming it into a knife of your choosing. Our classes of up to eight students are a great team-building experience and are suitable for all skill levels. Students will receive an induction covering basic use of the forge, blacksmithing tools and power tools along with standard workshop health & safety practices.
Class are run over Friday, Saturday and Sunday.
This class will cover:
After an introduction to metallurgy and the theory of pattern making, you will begin forge welding a 20 layered billet of 1070 and 15N20 steel using the power hammer. Once fused into a single block and drawn out it will be cut into 5 pieces, re-stacked, welded and then drawn out again to produce 100 layers.
The billet will then be surface textured to create your chosen pattern and then ground down too thin plate ready to begin forging the knife profile.
Once the knife profile has been forged you will use belt sanders to refine your knife profile, remove forge marks and clean back your blade. You will then select a handle material from our stocks or bring your own timber/handle material. Pick a fitting material, usually brass or perspex, and cut a slot for the tang of the blade.
The knife will be hardened and tempered to give it the hardness, toughness and flexibility it needs to perform as a knife. The blade will then be sanded thinner on the belt sanders and hand polished. Once the blade is polished it is left in acid to etch and revel the Damascus pattern.
Once the blade has been etched you will measure the handle material to fit the tang, glue the handle and use the belt sander to shape it to the desired size. Using sandpaper, sand the timber to a smooth finish, making sure to round sharp angles.
Sharpening - Finally, the blade will be sharpened ready for use.
- If you would like to bring your own timber please contact us prior to the class so we can advise on the suitability of your materials.