Cable Damascus

[Atlas Knife Company]

Being nearly finished with my dual burner forge, I'm almost ready to tackle my first damascus. I just bought 110' of 5/8" steel cable at an auction for $21. A bit small for cable damascus, but worthy of a trial. I thought I'd make a zip line for the kids with what I don't use for the damascus.

How do I prep the cable before heating and fluxing? I usually weld stock to a 3/8" rod when I forge. I figure I will need to weld the end of the cable THEN weld the rod to it. Should I weld both ends of the cable? It has lots of oil on it to prevent rust, and I figure I need to remove this. If necessary, vast amounts of carb cleaner is my first thought, soaking in acetone is also a possibility.

 

[Calvin Richardson]

I haven't ever done it but have studied it closely. I've been told that the grease that they use is very much like cosmoline and very difficult to remove. The gentleman that I discussed it with advise soaking in kerosene outside and the brushing the crpa out of it. As far as the size of the cable is concerned, you can always do a multibar billet. just alternate the twist pattern of the cable. Hope some of that helps.

 

[insanity]

I don't worry about cleaning off the grease. Most of it will burn off and anything left over will be removed by the flux.

Wayne Suhrbier

 

[MSCantrell]

Yep, I've done several feet of it and never cleaned it. I end up fluxing quite a few times before it's all said and done. Works for me.

(Also, I hear I'm a little out of the ordinary in this: I don't waste much time twisting it tighter in a vise, and I don't forge it square. I hit it in a half-round bottom fuller, and I just roll it in the direction of the twist, so that it gets a little tighter each time I hit it. It ends up solid and round- again, not square. So for what that's worth, it's effective and pretty easy.)

 

[Salem Straub]

I found soaking in kerosene helped, I've done with and without. Without is often fine, the grease etc. will burn off like mentioned above. Old scuzzy cable isn't really worth using, used cable is often fine though.

I've written up a tutorial on cable welding at my site, check it out if you like. Just got done banging some out the other night, it's not too tough. I find it's better to start with a big bundle like 3x2 pieces, weld the ends together first and then weld your handle on. With a larger bundle you may want to use at least 1/2" rebar for a handle, 5/8" would be better. I like starting out with a bigger stack as it affords the possibility of greater stock reduction before finished size. This always helps.

http://www.prometheanknives.com/shop-techniques-3/how-to-make-cable-damascus

 

[sunshadow]

I have some pretty nasty dirty oily cable. I just torched it into 8 inch lengths and when I want to make a billet I weld a handle on one end, start to heat it, put boric acid on it until it starts to glow, then I put 20 mule team Borax on, then I start to forge it down going with the lay of the strands until it welds solid. I get good billets that etch well.

-Page

 

[Atlas Knife Company]

Thanks guys. I started with Arriel's tutorial and have read Salem's also. The cable is new, still on the roll and looks like it has never been used. I just got an order for five forges, which I built this weekend, so I didn't get to it like I had hoped. I should be able to get to it next weekend and will post my results.