Making a Damascus San-Mai Kukri

Recent questions

• How is a Damascus San Mai kukri made?

  The Damascus San Mai kukri is crafted by layering three layers, two of which are Damascus, starting with 30 layers of alternating 1084 and 15 and 20. The layers are welded together with beads on corners and faces to prevent bowing, and the handle is welded to the Billet for stability. Quench oil is poured on the Billet before forging to create a protective soot layer, and the Billet is drawn out to around two feet, cut into six pieces for 180 layers. The Billet is then cut in half to sandwich three layers of 1084 in between, ensuring the core steel stays centered. The blade is thinned down, beveled, and ground with a unique pattern, followed by heat treating at specific temperatures for optimal hardness.

• What is the purpose of using a press in making a Damascus San Mai kukri?

  The press is used to isolate material for the blade and Tang in the process of making a Damascus San Mai kukri. It ensures alignment with the spine of the blade, allowing for precise shaping and control over the final product. By using a press, the craftsman can shape the blade and Tang according to the desired design and specifications, ensuring a high level of craftsmanship and quality in the finished kukri.

• How is the guard of a Damascus San Mai kukri crafted?

  Crafting the guard of a Damascus San Mai kukri involves ensuring flat transition faces, grinding the Tang to a shallower level than the ricasso, drilling holes with a quarter-inch drill bit, and connecting them with a round file. The guard is then shaped according to a leaf design, ensuring a unique and aesthetically pleasing appearance. Attention to detail and precision is crucial in crafting the guard to ensure a seamless and functional fit with the rest of the kukri.

• What materials are used in making the handle of a Damascus San Mai kukri?

  The handle of a Damascus San Mai kukri is crafted using a wooden block, copper, and epoxy. Holes are drilled into the wooden block, and sideward pressure is applied to connect them. Copper is inlaid into the softened tang to avoid difficulties later on, providing a durable and secure connection between the handle and the blade. The use of high-quality materials and meticulous craftsmanship ensures a strong and visually appealing handle for the kukri.

• What is the final step in completing a Damascus San Mai kukri?

  The final step in completing a Damascus San Mai kukri involves hand sanding all fittings, glueing up with 24-hour West system epoxy, drilling a hole for a stainless pin, hand sanding the handle, and darkening the guard with Perma Blue from Birchwood Casey. This meticulous process ensures that all components of the kukri are securely attached and finished to a high standard. The attention to detail in the final steps results in a beautifully crafted and functional Damascus San Mai kukri ready for use or display.