From the Volcanos of Nicaragua

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Jul 1, 2003
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Most of the BF regulars here have seen the work of Mike Deibert, a missionary-blacksmith who runs a vocational school outside Managua, Nicaragua. I met Mike a couple years ago, and have wanted to come down and teach at the school ever since. So last Wednesday I hopped on a plane and headed down to stay with Mike and his wife Lauren for about 8 days, teaching bladesmithing at the ESVO school.

What I taught, and how the guys are progressing will be the topic of another thread, but for now, I wanted to show something a little different. Even though I forge knives for a living, I am still rather green about the more ornamental elements of blacksmithing, and I have been bugging Mike since I arrived to watch him make something. Mike spends most of his time teaching, and less time actually forging than he used to, but from the few unsold items at the school to most of the furniture and hardware in his house, it's very obvious that he's a very accomplished blacksmith.

I would have been happy with a nice leaf or a rose or even a nice hook, but as the teaching slowed and the guys had a few hours to work on their own, i asked Mike what he really liked doing. I figure you get a better result when the artist is doing something that's really in his element. Mike said he really liked animal heads. That sounded cool, then I saw this horse head spoon on the workbench and said, "Man, this would look awesome with a head on the butt but a blade where the spoon is." And so was born this crazy project...

Of course they have horses here in Nicaragua, but more rare and more native to this very old land is the dragon who lives in the still active volcano a few miles from the shop. Mike has seen the old beast only once in his nine years here, but has never forgotten it's shape...



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Here's a shot of the volcano. The volcano is still active and you can take a tour to the rim and look down into the always-smoldering core at the bottom of the giant hole in the earth.


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So on day one, we started with the standard blade material of the ESVO school, the giant truck coil spring - 5160.



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This bar is a solid 3/4" dia bar, so it takes either some power forging tools (which they're fresh out of) or the next best thing, lots of hammers...



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Mike begins the creative forging at the anvil reducing the bar to a beast...
 
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The shape of the nose begins to form...



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The eyes and the nostrils are set with a punch...



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And the ears are split from the body. The chisels and punches he used the first time were immediately blunted when he used them. We re-sharpened them a couple times, with the same result. Then we figured out that once the dragon began to take form, the steel was no longer 5160, but had become some kind of prehistoric, draconian unobtanium which required a short trip to Mount Doom for some special tools. After that, all went well...

More later...
 
Awesome.
What a great trip.

side note: any laminated darksides coming?
i emailed you while you were gone.

continue, great story unfolding
 
This looks way too interesting not to follow to completion.

Burt, hope you will continue the narrative, it's really great so far.

Bob
 
Ok, more progress from day two...



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Mike stopped the dragon half way through so I could get the blade forged. It took some more gang hammering to get the stock down to a manageable size. I am a big guy, but I dislike hard work and avoid it when possible...



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Getting the blade shaped, starting to look like a knife.



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Just a bit off topic, but it gives a sense of scene. This was lunch today, before he was lunch. This has gotta piss a few people off, but when in Rome and all that. Kinda like very tough chicken. Beats starving to death...



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And this is the rough forged blade. We found a local iguana hunter who lives in the mountains and had seen the dragon asleep many years ago. He got a close enough look to describe the talons in detail and we worked very hard to duplicate the size and shape as much as possible. Tomorrow we get the dragon finished...
 
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Looks like you are having an experience of a lifetime there Burt! That iquana looks HUGE! The skin would probably make some fancy inlay material:D

Peter
 
Awesome stuff Burt, thanks for the pictures. I was wondering why you missed San Antonio, now it makes perfect sense. Glad you made the trip man, very cool.
 
And now, the dragon...



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Since dragons have notoriously deep throats, they need to be set with a special punch to insure realism...



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The mouth cut, and the lips formed on the anvil...



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A little final tweaking to get it perfect...



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And what's a dragon without a tongue. The tongue is formed separately, and will be attached later...



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And the blade is normailzed to get it ready for grinding and heat treating...
 
This is EXTREMELY cool!!!

Angi and I missed you in Texas, but I'm glad to see you were up to such good things!!! :)
 
And the grinding and finishing...


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One final trip for the old beast to his comfort zone...




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I just want to give a shout out to Rob Frink from KMG for making a great grinder, but come on Rob, you gotta put a guard on that top idler wheel to keep the lasers off my eyebrows!



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Doing the rough grinding. A few days ago, I took out the seven stitches I had in my thumb from a little slip with a knife a few days before I headed down...



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Adjusting that curve on the spine to match the curve of the real thing.



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Checking the blade finish with a critical eye.



I'll get the final updates posted after I get home tomorrow. Stay tuned...
 
Sounds like quite an adventure, Burt. I'm enjoying it from my perch up here and looking forward to seeing the rest.
 
That sounds like an inspirational trip. The knife is a very cool collaboration! Great artisans working together are capable of amazing things. Thank you for taking the time to share this with us. I cannot wait to see the finished product.
Thanks
Alden
 
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