Making a $5000 Mosaic Damascus Cleaver

Jesse Hu・2 minutes read

A detailed process of creating a mosaic Damascus Chinese cleaver, involving various forging techniques and meticulous attention to detail, resulting in a high-quality blade with a unique pattern and finish. The use of specific tools, welding methods, and finishing techniques, including hand-sanding and darkening the blade, to create a functional and aesthetically pleasing cleaver with a durable handle.

Insights

  • Bars cut into 6in pieces instead of 4in for more steel, crucial for creating mosaic Damascus Chinese Cleaver.
  • Mosaic Damascus requires multiple Forge welds, meticulous planning, and detailed execution to achieve the desired pattern and quality, showcasing the complexity and skill involved in bladesmithing.

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Recent questions

  • How is mosaic Damascus steel made?

    Through multiple Forge welds and detailed planning.

  • What is the purpose of using flux in bladesmithing?

    To prevent oxidation and repair broken Forge welds.

  • How is the hardness of a blade measured?

    Using the Rockwell Hardness Scale.

  • What is the significance of hand-sanding a blade?

    To achieve a smooth and polished finish.

  • How is the handle of a cleaver shaped?

    Thicker to accommodate the cleaver's size.

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Summary

00:00

"Bladesmithing with Surf Shark VPN Sponsor"

  • Video sponsored by Surf Shark VPN
  • Building a mosaic Damascus Chinese Cleaver
  • Bars cut into 6in pieces instead of 4in for more steel
  • Mosaic Damascus requires multiple Forge welds
  • Detailed pattern planned out on iPad
  • First Forge weld crucial to avoid flaws
  • Various processes in the bladesmithing community
  • Surf Shark VPN explained for internet protection
  • Using homemade squaring die to drag pattern closer to center
  • Studying electrical engineering at the University of Michigan

15:28

Forging and welding techniques for blades.

  • Pieces of sheet steel are cleaned with a d 80 grip belt on a grinder to prepare for welding.
  • Tiles are tacked close together and then welded around the entire Billet to prevent oxygen from entering.
  • The Billet is not dipped in quen oil but serves as a backup to prevent oxygen from entering.
  • After welding, the Billet is soaked in the Forge for a long time to set the forge welds.
  • Every bit of weld is ground off the Billet to ensure no mild steel remains in the Edge.
  • A technique learned from Salem Stob is used to create Forge welded bolsters from Mosaic tiles.
  • To widen the blade, a crosspin hammer is used instead of a Press for efficiency.
  • Flux is used to prevent oxidation and repair broken Forge welds, but it can damage the Forge.
  • Bolsters are tacked on and then Forge welded with flux before being dipped in oil for the quench.
  • The blade is ground to its final shape, ensuring no mild steel remains for a successful quench.

33:14

Handcrafted cleaver with intricate Damascus pattern

  • The blade was sanded to a 400 grit machine finish, taking up to 9 hours due to its size of 3.5 inches wide and 8.5 inches long.
  • The blade had a hardness of around 62 to 63 HRC and was hand-sanded at 150, 400, and 600 grit finishes.
  • A leather piece was attached to the hand-sanding stick to provide more give to the sandpaper.
  • The transition between the blade and the front of the bolster was emphasized for added depth to the piece.
  • The spine of the mosaic Damascus piece needed a high polish for a cool pattern effect.
  • The blade was darkened with Perma Blue after the Makers Mark was etched into it.
  • The handle was shaped thicker due to the cleaver's size, and the wood was ground without getting wet to maintain its density.
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