I still believe there is a valid market for this. Let's have an open-minded look at what would actually happen:
- Shipping costs: blanks would be easier to package, and less expensive. They could be simply tossed in with the rest of a shipment, or shipped separately in a smaller container. Even if it costs alot, it is still less than the cost of the full package - relatively speaking.
Cost decrease factor = .80
- Labor cost should be significantly less. Profiling, grinding and rudimentary finishing is still labor intensive, but is only part of a bigger picture. Even more so when you consider the Berk Special compared to an 18" WWI.
Cost decrease factor = .60 to .30 depending on complexity
- Managing the work should be easier too - just stop the work after the blade is shaped and given an edge. However, getting them to remember to do this, as well as agree to do it could be aggravating - so add in an aggravation factor. Plus, using up blade blanks mean underproduction of handle/sheath materials and extra management in inventory, etc. The reason for accounting for this is an increase in overhead by managers/supervisors, etc.
Cost increase factor = 1.20
- Material costs: obviously this would also decrease. Especially with knives with extra add-ons such as the YCS. Since you would get the khuk only, you wouldn't expect to get the karda - although that is and option, I guess...
Cost decrease factor = .7 to .4 depending on complexity
- Warranty - as mentioned before, eliminate the warranty as well as the "blem" category - WYSIWYG...everything "AS IS". No defects to worry about. Sure, I'd be disappointed at a failed blade, but at least I wouldn't have to tear apart a handle to regrind it. Of course, there have been relatively few failures, so who knows...
Cost decrease/increase factor = indeterminate
This would make an overall cost factor differential of .12 (low end) to .40 (high end). Or, rather, a blade blank should cost roughly 20-40% of the regular production price (on the HI site). This is high (as expected) compared to blade blanks from shops like Texasknives.com, jantzsupply.com, etc. where you can get blades for $15-$30 and turn around knives in the $50-$200 range. However, comparatively, quality handmade blades typically sell for $40 and up to $200 depending on the size and quality (not counting damascus).
So, let's give this a shot:
A 15" BAS is fairly commonplace in the production line and should be a good example.
shipping would be .8
the labor .5
management 1.1 (not too tough)
materials .7
total cost reduc = .31 or the blade would be roughly 30% of the full cost ($100)
blade blank = $30
Now, Bill regularly sells BAS blems for $50 - $75 so it's not very cost-effective for the buyer. Still, it's less than a full set.
Now, compare that with the YCS for example:
shipping .8
labor .5 (a tough blade to grind, but still less to do)
management 1.2 (already a pain to manage...)
materials .4 (no fancy inlays, etc)
total cost reduc = .19 or roughly $50
Now this is a great deal for a nice blade, considering its "potential". It would also be an easy sell because of the high demand.
This analysis is based on a few "given" factors:
- The blade blanks would have to be based on existing production lines and not new designs, etc.
- They would be manufactured on a hit-n-miss basis with neither regularity, consistency, nor "on demand" delivery.
- Kamis would probably not "sign" the blades since the blade would potentially come unfinished/unsharpened
- The blank would probably not be blessed (meaning: diff. level of concern/care)
- HI's overhead/profit would be the same as regular producst sold on the shopping site, and not blems, PGA's, etc.
Now, judging from the photos I've seen, the other 3rd world shops I've been in, and the people I've talked to, most of these handmade blade shops (that are successful) build their knives in a kit-like process anyway.
For example, one guy makes all the wood shields, one person generates the leather pieces, another one starts the steel profiling, etc. The person who takes credit for the knife still does most of the work, but not all of it. Additionally, most of their attention is likely split between the blade and the handle, and not the sheath.
Therefore, a blade blank should be an easy product to manufacture.
The only truly valid concern at this point (IMHO) is the interuption of regular business activities - a problem that Bill knows all too well. Part of what we pay for (as khuk buyers) is the long line of traditional production - that means, paying somebody to do the same thing over and over again, without change. This has driven costs down because of mass production and ease of operation (that's why custom orders are higher costs). When change comes, it can really send production into a spiral. I know this - I have seen it time and time again. IMHO, that's why Bill is reticent to approve a new idea. It would create yet another baby to babysit and would probably require lengthy phone calls ending in "Fine, Whatever." It's tough enough just to keep the guys doing the job at hand, let alone add another potentially confusing element to their task list.
However, all that said, I still think that producing blade blanks as an regular option is a good idea and a relatively untapped market that could be explored further. It won't be a profit-driving venture for HI, but would, with time, generate other return business - and that is the life-blood that keeps most businesses alive.
