Broken Arrow, you're absolutely right that the goal should be to get the "grindlines" as dead-perfect as on a classic Japanese piece. Now that they've got power grinding wheels this IS possible; a Mad Dog Panther is as clean as an old Katana and Kevin uses a bench-mounted powergrinder while holding the blade freehand.
Same tech the Kamis have now.
They just have to practice with grinders, and they need to physically see and handle an example of the quality level they need to strive for. That's being taken care of, Bill knows what I'm talking about.
I believe BirGhorka *should* branch out beyond Khukuris. The economics of what they're doing favors a higher average per-blade value because shipping and handling are identical for a $75 villager and a $300 "ultimate". HI shouldn't totally abandon the low end, because that's where new customers come from and HI's repeat biz is *excellent*.
Upshot: a small but steady stream of something worth $400 or so would be a welcome addition, serve as a "flagship product" and demonstration of ability and generate interest in the lower end goods too. The relative profit would be superb because Bill and the US crew would have to do only 1/4th the work as selling four $100 items, in terms of sales, inspection/cleanup, packing and shipping. Right now the flagship role is being handled by the extreme decorative pieces Bura does but...those aren't for all tastes.
The kamis are used to roles as "general purpose metalsmiths". In classic times they'd make farm implements, metal door hinges, bells, swords, spearheads, arrowheads, whatever. Make 'em "stick with khukuris" and they'll get bored out of their skulls
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Jim