Steve, I hope you will heal quickly and this will not affect your work. Sounds like a painful injury, and thank goodness you didn't lose a body part,

OR get injured even more seriously! That is a big blade to be flying around. Thanks for doing the right thing and speaking up.
Out of many, many, purchases, I have sent just two HI blades back, both by the same kami, both because of blade edges that were just totally out of line and unusable. One with the most beautiful antler handle I have ever seen. (Sigh! Forget the blade, I wanted to keep it for the handle LOL!) Both were cheerfully replaced by Yangdu.
Vim's first or second horribly crooked 13" Crow knife should never have left Nepal, and I probably should have sent it back, but I used it as a practice knife and ground it out and it looks pretty good now, being 3/4" shorter and several ounces lighter with a re-profiled handle as well. I etched it and was disappointed to find only half the blade hardened, but understand that practice has been changed for the "smaller" knives now, so that they are fully hardened along the edge. I have a half dozen of his later knives, including an 18" Crow, and as far as I'm concerned he sets the standard now for consistency and quality. Talk about a comeback!
I chopped a dozen times with my Museum Model and put it away. I am going to look it over carefully, then put on a heavy welding gauntlet and boots and pound on it some more tomorrow!
IMO Howard's excellent suggestion has been made before, and is absolutely the way to go. All organizations that really succeed and care about quality test their products. Of course being in SQA that's what I know and do, which admittedly skews my viewpoint, but that doesn't negate the validity of the observation.
A QC check of the blade alignment, chiruwa tang if applicable, handle and handle ring work, bolster, scabbard, and heavy blade testing should be made of every knife before it is ever UB ebgraved. That initialing should stand for something. It might add 5 minutes to the whole development cycle. HI has not done this because A) they have the best no BS warranty in the business, and B) blade failures are very rare in any case.
Still, there are other failures in manufacturing that can affect the public perception of quality that should be checked every time IMNSHO. If any knife fails on any point it should be rejected. Most of the occasional and mainly cosmetic problems listed below would subsequently disappear overnight.
When I pick up an HI or other kukri knife I look at several things:
I first look at the spine and check to see if it's straight or has waves in it.
I check to see if the spine is level, that is one side is not higher than the other, and if it supposed to be flat as with a big Crow, Malla or R-1, will use a square to check that.
I look down on the entire blade from the spine to see that the edge and the spine are in alignment; sometimes both can be dead straight on their own, but the blade edge not to be directly under the spine because it was pushed out during forging. This can cause the handle to turn in your hand when chopping (to the left if the blade turn is to the right, and vice versa.)
I flip it onto it's back and see if the handle north / south points are lined up with the edge of the blade (one of my pet peeves) and look down the edge to see if it wanders.
I look on both the top and bottom of the bolster to see if it is neatly formed and brazed, and if it slopes the same on both sides of the blade. On knives like the Uddha and R-1 with round bolster I check to see if it's uniformly round, or is canted one side or the other. I check the sword of shiva to see if it has been partially polished out or not, and is straight.
On swords like the Bhutan I check the guard to see if it is square on the top and bottom and lined up with the blade. The new Chit Bowie has the same type of guard.
On the HI katanas or other swords with a large guard I check the back of the guard to see if it has been polished out or is scratched and / or has laha on it.
If it's a chiruwa / panawal tang I check to see if the tang is polished on top and bottom, flush with the wood/antler/horn, and was also sanded smoothly
on the sides before the slabs were attached, so that it is both smooth and even on both sides of the tang. Many of the sides of those style tangs are rough and chewed up, which makes gaps and rough spots and peninsulas of metal when the handle slabs are fitted and then filled with laha to "hide" the gaps, which of course doesn't hide them at all but draws attention to the shortcut, which really looks bad I think. (If the tang is hidden, who cares if it's polished, but if it is to be seen then the extra work needs to happen.)
On the same type of handle I check to see if the handle pins are flush and polished. If not, they can usually be fixed, but what if it's a scrimmed handle?
On some few of the horn handles I have found a black putty was used to fill gaps, not laha, which I scrape out and replace with epoxy, as it will eventually usually fall out or shrink. Or, the more common finding is that any gaps are filled with dried red rouge from the buffer.
I feel for an edge on the buttcap. An edge to the bolster on the handle side, which will only be present if the handle was not correctly cut slightly oversize to the bolster. I check the sharpness with my thumb. I see if the cho is neatly cut and cleaned out of rouge.
I look at the handle circles near the ring and see if they are cut in a circle, and not in a loose wandering loop around the handle so that they run together and look sloppy, and that they are cut deep enough and not shallowly. I check the ring itself to see if it's uniform. If it's a knife like a Katunje or Chitlangi or Balance or Chainpuri with further handle markings I check to see if they are cut deeply and evenly, or if I will have to redo them. (Often on horn handles they will have been cut and then partially polished out.) I hold the knife and see if the handle ring is too far back or forward.
I put the knife in the scabbard and check if it is fitted properly, to the blade and not the bolster, so that the knife stays put when inverted as it absolutely should.
I check the karda / chakma holes to see if they are lined with leather so the little nails don't butcher the new handles.
I check the scabbard to see if the leather is smooth, the frog is sewn and fitted correctly, the frog hanger was cut evenly, and the chape was fitted properly to the scabbard with no gaps or sharp edges.
Finally (now, but I didn't always do this) I chop a little with it and slap the sides of the blade against the work to see how it feels in the hand and the blade holds up. For over two years I rarely did this, despite Yvsa and Uncle Bill and others repeated counsel to do so, so now have a great many HI knives that have never been tested at all or minimally. And still I don't do it as vigorously as Uncle Bill urged when I do do it. I really need to do this for all of them, but am afraid of what I'll find out I guess. Statistically I would probably have to replace 2 or maybe 3. But the fact is that every single knife I _have_ hard used has held up beautifully. Sure some dull quicker than others, but no failures or even edges turning.
Then, depending on the issues, I fix them. Usually there are none, or only minor, or just cosmetic that don't affect performance. Some I can't fix, but considering the value and price of HI stuff and the fact it's all handmade, I don't sweat it.
The only Kami that has never had any of the above issues for me is Sgt. Khadka. And I understand that he is not part of the main shop. I imagine being on his own he can take his sweet time and work on his own schedule which would help immensely. He does not do that many knives in any case when compared to Bura, Sher and Kumar, etc. (Actually, Khadka almost never applies leather to the karda / chakma holes, but he buries the brads so deep that they usually don't touch the handles.)
Sorry for the long post. I'll take my MM out tomorrow and pound on a railroad tie with it and see what happens. (Wish I had the supply of natural wood Munk and some of the rest of you have but that will have to do.)
We'll see what happens. Keeping my fingers crossed there won't be any problems; I love the look and feel of mine.
Steve, smoke going up for a quick recovery. Glad you're OK bud. And no one who knows you even the slightest would ever think you would call down a no-good $ grubbing lawyer on HI! (Oh! Sorry Berk! / Shann!

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Norm