Hand forged bolo/khukuri

Cliff Stamp

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This is a large brush blade owned by Andrew Lynch, similar in design to the Blackjack Marauder. It is hand forged to shape, without excessive grinding to finish. The blade shows evidence of the forging as there has not been a complete regrind to produce a smooth finish. The spine for example shows hammer marks as does the primary profile. As to exactly what you would call it, it isn't exactly a bolo, nor a khukuri, but sort of what you would get if you melded them together, but I am going to refer to it as a bolo anyway.

Here is a shot of it and a few other blades of similar general design to get an idea of its general size :

http://www.physics.mun.ca/~sstamp/images/al_bolo_bm_pab_ak_side.jpg

From top to bottom; an 18" Ang Khola khukuri from Himalayan Imports , Andrew's bolo/khukuri blade, a PAB from Strider, and a straight handled Battle Mistress from Busse Combat. Andrew's blade is a lot slimmer than the other blades and it is also more narrow as well, and is the only one with a distal taper. More details on those other blades can be seen in the reviews.

The mass of the blade is 700g and the balance point is four inches from the center of my grip, it isn't a light machete by any means. For reference the Battle Mistress is 660g and is balanced closer to my hand, three and a half inches, so you would expect it to be more neutrally balanced than the bolo - which is saying something. However the bolo feels lighter in hand than the Battle Mistress. The much wider grip on the bolo spreads out the force and thus there is less pressure induced. The blade came with a wooden scabbard, which does not hold the blade tight (turn it upside down and the blade will fall out), but is common on a lot of traditional blades.

The knife came with a very slight secondary edge bevel which I removed by blending the edge bevel back into the primary grind. I used a large x-coarse Japanese waterstone (5lbs) by hand and it quickly blended the bevels together, about a half hour or so. The edge was then sharpened using a couple of finer waterstones (1000 and 4000 grit). While I did not change the edge angle, the edge was weakened by the lightening of the shoulder which will reduce its ability to resist lateral loads. However this blending will also raise its cutting ability slightly. The main reason I did it was because on blades with convex grinds, secondary edge bevels will lead to edge thickening very quickly. I also ground the face of the guard a little as it was left almost sharp. Even then though it would not be something to choke up on for precise work as it is much too thin.

Before I did any heavy work I did some whittling on hard wood dowels to gauge its cutting ability ability. This was an unknown steel (probably spring), from an unknown maker of unknown RC, so it could have fallen apart on harder work quite quickly, so you start off light and work up. Anyway, the bolo pointed the dowels in 10.5 +/- 0.6 slices, which is very strong performance, the best I have seen in a knife this size without extensive modifications. I then did some chopping comparisons against the Gransfors Bruks Wildlife hatchet. The bolo had 91 +/- 3% of the hatchets raw chopping ability. You would need to be paying very close attention to notice the small difference in performance.

However beyond raw penetration, there was a large difference in feel and how they chopped through the wood. Specifically, the bolo had a higher tendency to glance. When the hatchet meets the wood there is a smooth transition as the edge cuts into and then through the wood. With the bolo, since the edge is curved it is more difficult to get a straight cut and it tends to pop out easier. It is just a matter of experience, after spending some time with the blade this ceased to be a problem. Most people will comment on this when they use such blades, like khukuris, for the first time.

However the handle leaves a lot to be desired. While it it nice and wide, it is boxy and gets slick quickly. There is also not a lot to drive off of at the end of the grip, nor much of a guard to prevent your hand from going forward. Though on blades of this class you don't generally do a lot of hard stabbing motions. I generally preferred to work with grip tape on the handle to increase security as even with a light rain the grip became slippery.

A khukuri of similar length as the bolo, such as the Ang Khola in the above, will have better penetration in the wood (~ 20%) and be much more fluid because of lower binding. So for felling and bucking I would readily prefer the khukuri. The khukuri is also much stronger and is a better splitter and pry bar. Of course such a blade is overkill for lighter vegetation and generates an extreme level of fatigue on lighter grasses and such. It is like swatting flies with a hammer. You can do it, but it tires you out quickly.

For general utility, the Battle Mistress is a superior choice as the curvature of the bolo makes some things very difficult. Trying to slice something on a cutting board (or whatever) for example is near impossible, and the additional blade length makes more precise work more awkward. The bolo truly excels chopping through light woody vegetation, such as limbing small trees. It is just a bit too heavy for grasses and such, though much better than the khukuri, and a bit too light for truly thick wood, but for limbing it is simply excellent.

I used it extensively in the fall of 2001 (through few cords of wood) and it easily outperformed the Battle Mistress for such work having a longer reach and a higher cutting ability for such work. The curvature acts to lock the vegetation in and there is no slipping along the edge. This in fact acts to increase the edge holding ability. It quickly became the blade I would choose for such work.

In regards to edge holding ability, and edge durability, while I started off very light, just working on soft woods, eventually I moved up to hacking through the hardest and knottiest wood around, which was seasoned dead fall, and which you can't cut as much as just break apart. The edge only tended to get damaged near the tip, and even there it just tended to get flattened. This isn't to such an extent that you could see it from the side, but you could note light reflecting. This could also be from dirt contacts as it only happened once in a while, however tips are often run softer on larger blades like these.

Lately (spring and summer 2002) I had been using a couple of large blades which I had modified to give the maximum level of limbing ability. The edges on these blades had been slimmed down significantly by me, often taking hours or work on a belt sander. They were ground down to the point at which they would dent if reduced further (as I did, and they did). I then ran the bolo against these blades to see how my impressions held up, as they were better cutters that what I was using last fall. The bolo held its own in terms of raw cutting ability, the only drawback was the boxy handle. After not working with the blade it for so long, and going heavy for around three hours, my ring finger started to show signs of irritation.

Getting specific about geometry, the very edge on the bolo is actually slightly more obtuse than on the other blades I was comparing it to (custom RTAK, Jungle knife etc. ). However the bolo was able to cut as well as them because of the nature of the primary grind which is dual convex. The blade tapers from about 2/3 height down to form the edge, and then back tapering along the upper 1/3 to reduce the spine thickness. This is the optimal shape to reduce drag. The concave blade curvature is also the ideal one for limbing. I recently thinned out my Battle Mistress again, and now it offered a greater limbing ability than the bolo, however the edge had to be ground much more acute, and the bolo still has the advantage of additional reach and the hooking action.

Here is the main profile of the bolo :

http://www.physics.mun.ca/~sstamp/images/al_blade_profile.gif

and a close up of the edge :

http://www.physics.mun.ca/~sstamp/images/al_edge_profile.gif

In short, the cutting ability is high, and the durability enough for the most extreme wood cutting as even hardened knots could not turn it. This is the only blade in a long time that I did not modify significantly from its NIB profile. The handle however could use some extensive work as it is not overly ergonomic nor secure. The sheath, while I didn't have any problems with it, would also probably not hold up to any kind of significant impacts without cracking, and could probably warp or split in humid extremes. It held up better than Kydex to the cold though. The blade will also rust rather easily if you don't oil it, which is expected for forged carbon steels. It is a simply excellent performer for cutting light to medium brush, boxy handle and all.

-Cliff
 
Cliff,

I don't know why more manufacturers don't produce a blade like this. How would you compare it's performance to that of the Becker Patrol Machete? Are you familiar with this blade?
 
First off Cliff, thank you very much for your work on this. I'm glad you liked the blade :D

Originally posted by Cliff Stamp
However the handle leaves a lot to be desired. While it it nice and wide, it is boxy and gets slick quickly. There is also not a lot to drive off of at the end of the grip, nor much of a guard to prevent your hand from going forward. Though on blades of this class you don't generally do a lot of hard stabbing motions. I generally preferred to work with grip tape on the handle to increase security as even with a light rain the grip became slippery.

I agree. It was far too boxy. However, I really did appreciate the width it has (a little over 1" IIRC), which is rare in a lot of today's high performance knives. Of course, that is subjective. I also didn't like how slick it was, but it wasn't a big problem for me. A basic lack of a forward guard didn't bother me.

Originally posted by Cliff Stamp
The sheath, while I didn't have any problems with it, would also probably not hold up to any kind of significant impacts without cracking, and could probably warp or split in humid extremes.

I agree, the sheath was really more of a safer way to carry the knife rather than a comfortable and effective knife retention system. It was really bare-bones as far as its design. I also agree it would not have been overly durable, but I think it could stand up to humidity fairly well. After all, I bought it from a Filipino JEST (Jungle Environment Survival Training, IIRC) guide and instructor who had been using it daily in the highly humid tropical rainforest of the Philippines for years. I think I paid $25 for it, and he was just as happy as I was about the deal :D

Blademan 13, I concur! The Patrol Machete is the closest thing I've used so far, but doesn't quite have the durablity of the bolo, IMHO. I would love to see more blades like that bolo (but improved...like better handles and perhaps steel).

Thanks Cliff!
 
Cliff- I can't wait until you get your hands on a Cold Steel ATC. I am anxious to hear how it stacks up to these other similar models in your rigorous testing.

I, too, wish that more companies would offer similar knives. I love these kinds of blades and own many similar models by quite a few manufacturers. I really wish Camillus would release something like this under the Becker line... something comparable to the CS ATC or the BJ Marauder or even a Hays Parachete. Curved blade, huge belly, distal taper and a full flat grind on a 9-10" blade would be nice. I know Becker thinks a lot of their Machax but I am not too impressed with its performance as compared to others in that class from personal (and from reading Cliff's) experiences.

Peace-
Cam
 
I know Becker thinks a lot of their Machax but I am not too impressed with its performance as compared to others in that class

The Becker Brute might be a closer match.

n2s
 
The Brute is a decent chopper but even with its shortcomings the Machax outperforms it at that task.

Peace-
Cam
 
Blademan13 :

I don't know why more manufacturers don't produce a blade like this.

There is probably not much of a market. This is a simple using blade, not "tactical", and highly optomized. Also, as Greenjacket noted, from a durability standpoint, this blade presents a fairly extreme challenge to a maker. Further, you could argue that the market for such a blade would be dominated by cheaper working class tools. The kind for example that you would buy to give to a summer work crew and regard them as throw away expenses, as you can get cheap machetes for $5-10$ each. A simple machete is going to win every time here because of the cost advantage of not having to make a primary grind and work with cheaper steel.

However, you will gain performance in many ways by going high end, especially if use a double convex taper on spring steel. The cutting ability will increase, as will the gross blade durability and edge durability. Sharpening freqency and duration will also be reduced, and overall induced fatigue will be lower because of all of the above plus such issues as lower induce shock and vibration. The overall lifetime of the blade will also be greatly extended as the cutting profile doesn't significantly change with sharpenings. It is common for example with blades made like this to be used for 20 years or more and be passed down. They typically get delegated to different use as they are slimmed out.

In contrast, a typical soft machete (~45 RC), will see significant changes in profile quickly using traditional sharpening on a coarse file. Getting specific, I have a Tramontina Bolo which I need to sharpen after a mornings work on woody vegetation. By then it is down to ~30% of its optimal sharpness (on cutting 1/4" poly under a 1000 g load). At this point it still works well on thick wood, but it can't cut the lighter brush well . Now since every filing removes ~1/10 of a mm of metal, in a month, I am up to ~1/4" of blade lost. There are ways to reduce this wear, using a butchers steel for example in between filings, but the basic point remains. Of course when a blade costs $5 do you care if you have to replace it once a year, and even if it does break, just just buy a couple at a time to have on hand.

How would you compare it's performance to that of the Becker Patrol Machete?

I also found the handle on the Patrol Machete slick, however much more ergonomic, in a completely different class. The Becker isn't however even close in regards to durability. There is both a vast difference in steel, heat treatment, and most importantly geometry. I have grossly damaged two Patrol Machetes with use that is about 25% of the maximum that the above bolo has seen. I am ballparking the latter, it is well under half, and above 10%, to be more specific (<a href="http://www.bladeforums.com/forums/showthread.php?s=&threadid=194054">more details</a>)

The bolo has a more acute edge and thus can do a lot of fine work much easier. Sweeping off light vegetation it is much more efficient than the Patrol Machete for example. However on on felling thick wood, where the penetration approaches 2" for both blades, they are very similar in performance as the Patrol Machete has a more acute primary grind. Of course you could just slim the edge out on the Patrol Machete and thus raise its shallow cutting ability. For the type of vegetation it is suited for, I would cut the edge angle roughly in half. The Patrol Machete will bind more readily in thicker wood, but not so much that I would rate it a huge disadvantage. On harder wood it becomes more of a problem. It has the same hooking action as the bolo.

Andrew :

I think I paid $25 for it, and he was just as happy as I was about the deal

Sounds like quite a deal to me. A US custom is going to cost you about 10x that. I agree with the handle, issues, I would not rate them as overly critical. With some grip tape, and a few sessions to get my hands back into shape for those particular lines, comfort and security are fine.

Orion, I could not agree more. I have been after Busse for quite some time for such a blade as well. There is some hinting now that there might be a Swamp Rat khukuri. This is rather high end though, roughly double the price of the Patrol Machete I would expect.

I have a bunch of large blades coming from Martindale that will be interesting to look at as well. Of course they don't have a primary grind, but I have a few 40 grit ZO belts that will fix that. The low RC sets a higher bound for the edge durability, but strength increases rapidly with cross section, so we won't lose too much cutting ability.

In regards to the Brute/Machax, you are looking at a many to one drop in cutting ability over the above blade, and less than 50% of the chopping ability, penetration wise. Of course they bind a lot less, so the comparison would be more in their favor on really soft wood. You can of course just back off in force used on the slimmer blades as the wood gets softer. The Brute/Machax of course make a better splitter, and dedicated prybar, however you would have to stand on the above blade to break it off, and I would assume it would just bend if you did.

-Cliff
 
i had read an article some years ago about this course in the philapines, the instructors made the knives out of the springs of old military trucks, and they were noted for the environment they were in that they outperformed many of the higher priced blades as they were easily sharpened and took the shock of chopping very well. i think it was in SOF, and written by a person that had taken the course.

alex
 
Yes, forged spring steel is an excellent choice for such blades. That they offer such high performance isn't surprising when you consider that it is the only goal of the design. They are obviously not influenced by promotional aspects at all so there are no compromises made. Sal Glesser noted for example that sabre grinds sell better than the fully flat ground folders. They of course cut much worse, and thus offer lower performance, but to many they look better and that is a significant factor in what is bought.

-Cliff
 
Cliff, another well observed article, thanks I enjoyed the read. Much mirrors my experience with my Blackjack MarauderII (out of production, the handles great). These are the hard wood machetes, as I like to call them, that I would love to see more custom/manufacturers produce. They are a real test for those makers who want a challendge. Though how big the market is I don't know? They are quite specialised but do excel at limbing out the stuff thats too much for a machete but not enough for an axe. And they have that all important reach over shorter stouter blades. I don't know if you found it, but I find them great fun to use.

A general warning for all. These heavier bolos do ricochet off, glance off, like a machete when you make a bad hit. Easily done if you tire. Being heavier you do need to watch out as the swing is difficult to check. Consider where your feet are positioned and think before you start hacking away. Safety clothing/boots are probably not a bad idea. Be careful.
 
Andrew is this blade still getting some use? It was one of the few large blades of that class I have used which didn't have problems with limbing while having a very thin and acute edge profile.

-Cliff
 
Cliff...
I guess Swamp Rat never came out with the Kuk.... maybe still in the works...?

Are you familiar with Bark River stuff? They are coming out with a kuk earlier next year. Looking forward to that.

I just got a WASP by Newt Livesay for my birthday. Haven't used it yet. Have you ever played with one of those?

Peace-
Cam
 
The closest Swamp Rat came out with was the Rat Daddy which is still a bit short for a brush blade. Hopefully the Scrap Yard line will have a longer blade of suitable profile, S7 is a very nice steel for it. You get a blade which has much better impaction resistance than the usual heavy machetes which are spring hardened so it will not dent/roll as easy. You also get better wear and corrosion resistance.

I am indirectly familiar with the Bark River knives through use of a Blackjack small which has the same type of full convex primary profile. The goloks from Bark River look really nice. It would be nice to see a comparison vs Valiant which has the same pattern in a traditional forged blade. I really like the cutting and handling ability of the Valiants but had problems with durability even on what I would consider to be light work. Blackjack also has a nice looking khukuri as well.

I have used a Livesay RCM and RTAK. Solid working blades. I had a problem with the RCM as the steel was defective in one spot but the RTAK was solid. The edge was *really* heavy though at 0.080" thick. I read similar comments on rec.knives about the profiles. Livesay did promote a heavy "tactical" aspect to those knives which were supposed to withstand very heavy use but even then that profile is really overbuilt. As far as I know he isn't making knives any more.


-Cliff
 
I recently used an Ontario RTAK to do some limbing work on a spruce tree I took down in my yard. After taking off a few limbs about two inches in diameter I noticed the chopping ability had decreased significantly. When I checked the blade to see if it had dulled I was very surprised to find two large chunks missing from the edge. I am talking larger than a dime in size, just big semi circles of missing steel.

I believe the RTAK is 1095, and I had used it once before to limb some alder and did not have a problem. While I did induce some lateral stress while pulling the blade free from the spruce limbs, I would not characterize it as unusual or abusive. I say this because you can never tell how a knife is going to perform until you use it in real life situations. It may be this particular RTAK was heat treated incorrectly making it brittle, but needless to say I will not be buying another one. BTW, I switched to a Busse FSH and had no further problems.
 
I saw the same thing with two Ontario machetes, immediately fractured. I also saw brittleness with other Ontario blades as well and then problems with lack of hardness and tangs bending, so the variation is quite wide. The Ontario RTAK I had saw damage pretty much immediately in even light wood working. The edge didn't break apart but rippled right away because the variance was so high it dipped way too thin and there was no strength. Sometimes a measurement can tell if there is going to be a problem, but if it is a steel/hardening problem you have to use it.

-Cliff
 
Yeah, I think my RTAK was simply too hard for the knife's intended use (chopping). The way it broke the pattern reminded me of glass or ceramic material failure. I have a picture I will post later. 1095 can be a very good steel for a variety of uses, but I think the heat treat has to match the use. Too bad the blade failed. I really liked the design.
 
At the hardness Ontario specifies for these blades it should be very tough. It is likely too long after quench before temper or over heating as 1095 is very easy to oversoak and induce the grain to coarsen. Considering how low Ontario is running these blades they should drop down to 1045 or similar anyway or ideally use salt pots and run bainite in a suitable steel.

I like that general length of blade, I didn't like the handle design and prefer a more solid tip on blades of that class, mainly to pry apart dead woods and such. Livesay noted the RTAK's were prone to tip failure which is why he redesigned it for the AK series. He also reworked the grip due to ergonomic and security concerns. Too bad he had problems as a maker, he had clean designs and very low prices.

-Cliff
 
Yeah, I tend to agree about the tip on the RTAK. But a sharper tip does come in handy in some situations, but then one could use a smaller knife for that chore. As for the handle, I didn't like it at first, but the more I used it I found the larger grip didn't induce blistering as much as a thinner grip. It's kind of like a tennis racket, too small a grip will cause blisters quickly because the skin gets bunched and then it rubs against itself, while a larger grip stretches the skin out and prevents this from happening. You can still get friction blisters from the handle itself though. I recently obtained a Siegle Hoodlum in 5160 and I am looking forward to trying it out. The handle is somewhat similar to the RTAK, but in G10, and the blade is about the same length. but definitely thicker and recurved a bit. Theoretically it should chop very well.
 
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