I went over Howard's site with great interest. It seems real obvious this guy IS Bugei's supplier, although I didn't see it mentioned. That's probably in their contract...but prices on the 1086 and folded blades (per inch) are identical to Bugei's prices on unfinished blades.
Now, there's a Clark blade type in TOOL STEEL at a GREAT price (same as 1086) that Bugei isn't buying, probably because the stuff won't take a hamon (temper line, often viewed in Japanese swordcraft as a decorative enhancement). If I was ordering a Clark blade, that would be THE way to go! Includes some "springy" properties not normally seen on a Japanese-pattern blade.
Also: take a look at the "pre-made stuff people didn't want and is available cheep" area. Notice how some are abnormally short and/or have *monster* tangs? Both are strong signs he's got customers in the Bujinkan and/or related Jinenkan/Genbunkan scenes...long grips and somewhat short blades are hallmarks of such stylists, of which I'm a definate beginner
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What else...as to "what's going on in Phil's head", first off he's trying to do pieces that are lighter yet tougher than traditional, mainly by using tool steel (A2). Through some unknown alchemy he's made it take a hamon, which may be unique. I've seen some literature on his peices that talk about how "any modern swordsman ain't gonna be in armor" and hence lighter means faster means better. The chisel grind may have something to with strength with a smaller overall steel area? I have no idea what style he's trained/training in, but it's a "short grip" system; he's either not familiar with or not interested in "long grip" systems where the blade weight can be a bit higher and you've got the leverage to not hardly notice. Long grips (measured to the user's forearm, my Alan Folts-ground piece will sport a 15" grip!) are typical of the "feudal warring period"...later Edo swordsmanship was more "personal combat/dueling" and carry *everywhere* (and a shorter grip) became popular.
Jim March