Forging a kukri

[weo]

Hello all. A buddy of mine wants me to push my abilities and forge him 3 damascus knives, one of them a kukri. My plan is a 12"-ish blade, and 4" hidden tang. I'm also going to shoot for an integral. I currently have 2 billets of 5160/15N20 - 0.375"x 1.375" one at 75 layers and one at 35 layers. My questions:
What would be a good billet size to forge this blade?
I tend to forge a bit thin (make mostly kitchen knives) so what thickness should I shoot for as final forged thickness?
Thanks.

 

[Stacy E. Apelt - Bladesmith]

In a normal blade, you have to bend the billet down to allow for the lift of the tip as you forge the bevels. In a kukri, you have to add more to allow for the bend downward. Work with thick stock on a kukri. 1/4" is thin, 3/8" isn't overly heavy. When done grinding 3/16" to 5/16" is about right. Forge to basic shape and grind in the bevels and details.

 

[Tom Lewis]

I would use 1084 or 01 with the 15N20. In my experience 5160 Is harder to weld.

 

[weo]

I would use 1084 or 01 with the 15N20. In my experience 5160 Is harder to weld.

That's what I've heard, but I was out of O1, 1084 and 1095, so these are the billets I've got.

 

[mete]

My big kukri is similar to the military one 12" blade with a 1/4 " spine and about 24 oz finished weight .It really depends on what kind of jungle you have to cut ! Mine certainly can cut some serious jungle .My smaller one is 16 oz and that much less cutting force. For heavy use I would also like 1084.