Oh, boy, I'm enjoying making these. Learning new things each step of the process. Then again, I'm still fairly new at making knives. My knowledge still outweighs my skill, but not my desire to learn more. I've never tried a katana. Then again, there are lots of styles that I haven't tried. I've yet to make a large damascus hunter, anything with curly maple, and for that matter I haven't forged the titanium camping utensils that I've been thinking about, either. So, I made a katana. Well, a katana blade, anyway.
I had a piece of 400 layer damascus that someone gave me last year. I cut off a 1/4" piece from the end and welded it to a rod and started forging. Absolute gut wrenching, watching the first hammer strike split the layers into five different pieces, each about 80 layers thick. One piece of the damascus was still flat, the rest were ruined and had to be cut off. Obviously I don't get to draw this out to the length I had predicted. Fortunately, the piece was about 1/16" thick still, plenty to draw out to a 1/32" thick blade. Using a smallish hammer, I forged it out to a nice hunter shaped blade, 2.5" long. There seemed to be a small imperfection in the steel, lengthwise down the blade near the edge. I annealed the piece and cut down the middle, leaving a long, skinny piece. "Hmmm, looks like an itty bitty katana like Stacy makes," I thought. I take it to the grinder and sure enough, I'm able to save a sweet little katana a little over 2" long. HT at non-magnetic for 60 seconds and quench. Straight as an arrow.
Now, how do I make a guard. Normally, I grab a piece of titanium and drill a hole. I grab a piece of titanium and drill the smallest hole I can. I slip the tang into it and quickly realize I need a much smaller drill bit. This isn't working, I realize, and it will never work. I see a picture of the screwdriver made into a punch and give it a try. Way too small and bits of steel go flying when I tap with a hammer. I look at Stacy's katana WIP and realize that it's not steel, it looks more like copper. I grab a pre-1982 penny and hammer it flat. Using another screwdriver, I punch a nice tang shaped hole in it. Nearly perfect. Just a little fine tuning, and I have a guard.
Where the metal flares out even looks like the part of a katana that covers the ricasso. Tsuba, suki, tsu-chi, whatever it's called, I hope that someday when I make a full scale katana it looks as good as this one does. Yes, I know it's called a habaki and should be a separate part from the tsuba and seppas. I don't have the needed tools to do this at this scale. Now, I just need to build a tsuka. (sarcasm)That should be easy, right?(/sarcasm)
I finished sanding the blade at 13 micron and can't see any damascus layers. I haven't etched yet, and don't want to until I'm ready to glue the handle on. But, remember the piece that I cut off the original blade that had the imperfection? Well, I decided to sand it and see what kind of pattern I have. 5 minutes sanding and 5 minutes in the acid and. . . .NOTHING! Well, I know you have to HT damascus to get a good etch, so I HT the piece with a torch and quench in water. 2 minutes sanding the scale off and 5 minutes in the acid. Still nothing. Hmmm, this is weird. I know it's layered, it split into layers when I forged it. I get out my USB microscope and become very happy.
If I get this finished in time, this will be my entry for the KITH. If not, the koa handled hunter will be entered. Attached is the current pic of the blade and the piece of damascus that I test etched.