Applying the clay:
Make a simple stand/clamp that will hold the blade by the tang and allow you to work with both hands. The ability to rotate the blade and work both sides is important. A trip to Harbor Freight will yield some inexpensive clamps that rotate. Mount the clamp firmly so you can sit or stand by the blade and do the clay work.
If you are married, or have a good partner, Don't do clay coating in the kitchen.
I recommend that you use satanite for the clay. You will read about AP-green, Atlas/Rutland furnace cement, etc., but satanite is cheap, reliable, and works perfect.
Make a thin mix, about like heavy cream, and apply a wash to the whole blade. Dry with a hair dryer or heat gun.
Thicken the mix with more satanite until it is about like sour cream. Apply this to the spine area, bringing it down toward the edge. Stop about 1/4" before the edge. Do the same to the other side. Use a popsicle stick to smooth the layers to about 1/16" to 1/8" thick. Take your fingers and wipe the edge in a straight line, removing the excess along the edge. This will leave the ha exposed for about 1/4". The pattern you leave in the exposed steel will shape the hamon. Dry the blade with the hair dryer.
Note: If you as doing a blade that you wish to control sori somewhat, you can wipe the satanite off the mune (spine).
Do yaki-ire as desired, keeping the austenitizing temperature on the lower side. For example, 1070 says "1450°-1525°F" Try 1450°F.
After quench, clean the blade and examine the edges for ha-giri - tiny cracks running from the edge inward. If there, discard the blade and start again.
After a snap temper, a light sanding, followed by a quick dip in FC may show the potential hamon line. This is not the final result, just a confirmation of different structures in the blade.
If inspection goes well, do the final shitaji-togi (foundation polishing) - the hamon may not be visible at all at this point. Get all the shaping right at this stage. Removal of excess metal will not be possible in the next stage.
Please Note:
The blade will be getting sharp as you do togi. Use caution as you go, and extreme caution in the final stages of shiage-togi. Misuse of things like hazuya stones and nugui can lead to having no fingerprints ... or fingertips if not done right. Doing a hybrid polish instead of traditional togi on your first several blades is a good idea.
Continue onto shiage-togi (finish polishing), where the hamon will start to re-appear.
Use of a variety of methods and etchants can bring the subtleties of the hamon out in the final steps. Ther are many articles and threads on doing this
General notes:
The hamon will not be exactly where the clay stops. Experience, and your own equipment will teach you how to place the hamon.
If the hamon does not appear to have developed, re-do the clay work and HT.
Note that fast oil is safer, but any hamon will be faint or may not exist at all. Brine will develop the best activity (hataraki). Brine will crack some blades until you get it mastered ... somewhat. Water is wonderful for a hamon, but will break a lot of blades.
More complex hamon, greater hataraki, ashi, and other features can be developed by changing the shape of the edge of the thicker clay line. Make the line wavy and you can get notare; poke it with a stick into small ridges and get Choji or many other patterns; make small lines to the edge with a slightly thinned slurry and create ashi.
Another thing that affects the hamon is the niku (meat) of the blade toward the edge. The amount of thickness and grind shape toward the edge affects the quench and how fast the steel cools. I like a slight apple-seed grind.
Info for polishing the hamon:
I have several articles on hybrid polishing but a short list of the agents that will help develop a hamon are:
Diluted HCl ( 100:1), FC, lemon juice
chromium oxide
red iron oxide
black iron oxide (magnetite)
tin oxide, FC
fine SC grit
3M polishing papers ( 400-8000)
Choji or other pure oil
Flitz polish
1.25" round gun cleaning patches.....lots of them!
Other supplies:
White enamel paint (Testors) and finer sable brushes
popsicle sticks
Tough painters tape to mask areas off (Frog tape)
There are several good books on the subject, and some good DVD's.
A few are:
Walter Sorrells - Hamon (and his entire set on Japanese blades)
Setsuo Takaiwa - The Art of Japanese Sword Polishing (I highly recommend this book)
Clive Sinclaire - Samurai Swords
yaki-ire isn't something you just do and are done. After the claying and quench you need to remove the surface metal and expose the transitions between the martensite and pearlite plus etch to expose the crystals of nie and nioi. The polishing and etching are what exposes the hamon. (I'm probably the last guy alive who still refers to these structures as Troosite)
After quench and removal of the clay you don't have a hamon. You have a quenched blade with surface decarb-oxides-and other features. The transition where the clay line was is often topographical (it is also not likely to be where the actual hamon is). This is just the start and not the finished product. All that surface has to be removed.
After quench and some basic cleanup to 400 grit you may see the hamon sometimes. Often you will see nothing until it is etched. Even if you see it, it isn't usually all that is there.
Use a low alloy low manganese steel. My order of preference for readily available steels is - Hitachi white paper, W-2 (low Mn), 26C3.
Etch with very weak acids. 10:1 FC up to 15:1 is a good hamon etchant for most folks.
100:1 nitric acid is also good.
Other acids used are fresh lemon juice and white vinegar.
The etchant is often worked along the hamon features by rubbing with a pad soaked in the acid. Wear gloves if you don't want stained fingers and mushy skin. Makeup cleaning pads and gun cleaning pads are perfect for shiagi-togi task.
Clay wash with a very thin clay mix and then clay the proposed hamon THIN. 1/16" is more than enough. 1/8" and thicker are far too thick. The hamon does not fall exactly on the clay line and some experimentation will be needed to place it where you want. Steel thickness greatly controls the movement of the hamon (as well as alloying),
Let the clay dry! Use a hair dryer of fan if needed, but let it completely dry before putting in the oven or forge. Fast drying in the forge or flames isn't a good idea. If the clay cracks and falls off too soon in the quench, the spine will cool too fast, and the blade can form no sori ... or even negative sori.
Austenitize on the lower range of the steel using. If the hardening range is 1445° to 1490°, use 1445°. An oven is far better than a forge for this.
Quench in a fast oil. I recommend Parks #50.
Brine is an extreme quenchant and can crack blades. It makes a great hamon, but takes its toll on your nerves and blades. No one like the dreaded TINK.
Interrupt the quench - IN 1--2-3, OUT 1-2-3, Back in until cooled. You may have to experiment with the timing.
Develop the hamon by selective hand polishing with very fine powders. Ther is a whole array of oxides and grit compounds used to get different looks.
I like a frosty duller and darker finish above the hamon (ji) and a shiny polish below (ha). Use the corner of a folded makeup pad to work the area below and above the hamon line to get shiny bright and darker areas. Use a different pad for each compound/oxide. Selective final etching post-polishing can greatly accentuate the light/dark look.
After the first light polishing of the whole blade (somewhere between 400 grit and 1000) leave the actual hamon line alone and work the areas above and below it. This creates a frosted white line for the hamon.
NEVER buff a hamon on a polishing wheel buff. It will wipe out most of the visible details and you will have to start polishing again.
Pro-polishing tips - Use glass or plastic "petri dish" containers for the polishes and oxides. Keep the pad used with that compound in the dish. They stack neatly and store in a plastic small box with all your other hamon polishing supplies. A 20 pack is $10.
Use a pointed popsicle stick on the pad for polishing small and tight areas along the hamon or ashi. I like 22 calibre gun gleaning pads for these areas.
Empty and refill the water dip bowl when you change grits/oxides/compounds.
Use nail polish or model paint to mask the hamon and ashi as needed while polishing above and below it. Remove it with acetone or other solvent when done.