Forging a Copper Damascus Katana

Tyrell Knifeworks2 minutes read

A "cumai" katana is crafted using twisted damascus with 1095 and 15n20 steels, starting with a billet forged in kerosene before being shaped, twisted, and flattened to create a specific pattern. The process also involves blackening steel fittings with hot salts, engraving a maker's mark, wrapping the handle, and constructing a scabbard through milling, gluing, shaping, sanding, and painting for the final product.

Insights

  • The process of building a "cumai" katana involves intricate steps such as forge welding a billet of 1095 and 15n20 steels, twisting the bars to create a unique pattern, and using a hydraulic press for forging.
  • To complete the katana, additional steps include blackening steel fittings with hot salts, engraving a maker's mark and "Tyrell Knifeworks" in Japanese on the blade, constructing a scabbard through milling, adding felt for protection, shaping, sanding, and painting the final product.

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Recent questions

  • How is a "cumai" katana made?

    By using twisted damascus with 1095 and 15n20 steels.

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Summary

00:00

Creating a "cumai" katana with damascus

  • Building a "cumai" katana involves using twisted damascus with 1095 and 15n20 steels.
  • The starting billet consists of 1095 steel in black and 15n20 steel in white.
  • After a dip in kerosene for forge welding, the billet is heated and squished to set the weld.
  • A 30-ton hydraulic press is used for forging the billet into a square bar.
  • The bar is squared on the diagonal and then re-squared to introduce a curve.
  • Twisted bars are rounded before actual twisting to avoid sharp edges.
  • Twisting is done using a pipe wrench after heating the steel.
  • The twisted bars are forged flat to achieve a specific pattern.
  • Kiss blocks are used on a press for consistent thickness down the billet.
  • The billet is stretched and flattened repeatedly to reach the desired length and thickness.

21:56

"Blacken steel fittings, engrave, construct scabbard"

  • Use hot salts to blacken steel fittings by soaking them for 15 minutes, then proceed to wrap the handle. Engrave a maker's mark and "Tyrell Knifeworks" in Japanese on the blade, wash it in acetone, dip it in acid, then hot coffee to blacken it. Construct a scabbard by milling two halves, adding felt inside for blade protection, gluing, shaping, sanding, and painting it for the final product.
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