I've been to the shop and saw the knives from birth to shipping.
Kevin indeed does 99% of the work, and all by hand. He purchases the raw Starlett 0-1 steel in long strips and he (or one of his guys) cut them into the shape for the particular model that is on order. When I was there it looked like he does a handful of models at a time, not really any huge "runs" of a particular model.
They are heat treated right in the shop, usually one at a time, there are no huge "racks of knives" where scores are done at once. Each one is given individual attention.
He then grinds them by hand. I sat and watched and entire grinding and was amazed at how long it takes and how physical it is. It is a long, patient process. Grind, grind, grind, cool it down, paint it up with some blue reference dye stuff, then grind, grind, repeat.
The handles start out as these huge blocks of composite and Kevin grinds them into shape. What is amazing is that he does it all by eye and feel, no patterns or anything. This explains the subtle handle variations between identical models.
The only time they go out of the shop is for the hard chroming. Kevin seems fanantical about the QA on these things and keeps a close relationship with the chrome folks, he doesn't just go with the low bidder.
They come back all happily chromed and then the sharpening process starts.
Kevin is absolutely the only guy that does the grinding.
While I was there the other guys that work for him only seemed to be doing Kydex stuff as well as the shipping and packaging, etc. I never saw anyone touch a knife except for Kevin.
After this I walked away having a whole new respect for hand-made knives and the people that make them. I'm amazed that these makers can put out as many as they do.
This is a first-hand account with my own eyes.
--Doug