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Knifemaking - Making a Chain San Mai Damascus Machete
Making a big san mai damascus machete with chain sides. This is the biggest piece I've done in this type of damascus so far.

Order Details:
-12" blade, 18" overall length in the profile my customer supplied.
-Chain San Mai Damascus with 5160 core steel.
-Handle in texturized micarta.
-Take down screws instead of pins (customer wants to send the knife to Ionbond for a boron carbide treatment)
-Hand stitched and worked leather sheath.

Knife making process
12 pieces of motorcycle chain cut to measure 9" each. (Pictures 1 and 2)

Soldiered in groups of 3 chains each. (Picture 3)

Soldiered the previous groups, one on top of the other. Now I have 2 groups of 6 pieces of chain each. (Picture 4)

In the oven at 850 C (Picture 5)

I press the group between flat dies to compress the intersticial space between links. (Pictures 6 and 7)

Each group, already pressed. (Picture 8)
Knifemaking - Making a Chain San Mai Damascus Machete   Knifemaking - Making a Chain San Mai Damascus Machete   Knifemaking - Making a Chain San Mai Damascus Machete   Knifemaking - Making a Chain San Mai Damascus Machete   Knifemaking - Making a Chain San Mai Damascus Machete   Knifemaking - Making a Chain San Mai Damascus Machete   Knifemaking - Making a Chain San Mai Damascus Machete   Knifemaking - Making a Chain San Mai Damascus Machete
Picture 1   Picture 2   Picture 3   Picture 4   Picture 5   Picture 6   Picture 7   Picture 8
Now I place those chain groups on the sides of a 1/4" 5160 flatsheet and soldier on the ends to fix them in place. (Picture 9)

Then I make a square section cannister. (Picture 10)

And then I place the package of steel inside it and then close it. (Picture 11)

In the oven at 1300 C (Picture 12)

Press welding the package. (Pictures 13 and 14)

I then get rid of the cannister easily (thanks to a sheet of 0.5mm thickness in 304 stainless I've placed against each side. (Picture 15)

Package out of its container (Picture 16)
Knifemaking - Making a Chain San Mai Damascus Machete   Knifemaking - Making a Chain San Mai Damascus Machete   Knifemaking - Making a Chain San Mai Damascus Machete   Knifemaking - Making a Chain San Mai Damascus Machete   Knifemaking - Making a Chain San Mai Damascus Machete   Knifemaking - Making a Chain San Mai Damascus Machete   Knifemaking - Making a Chain San Mai Damascus Machete   Knifemaking - Making a Chain San Mai Damascus Machete
Picture 9   Picture 10   Picture 11   Picture 12   Picture 13   Picture 14   Picture 15   Picture 16
Flattening to the desired thickness. (Pictures 17, 18, 19 and 20)

Customer supplied drawing placed in top of the damascus bar. For this type of damascus, forging to shape might be detrimental to the knife, so I just cut it to shape. (Picture 21)

Ground, drilled and tempered blade before getting into the ferric perclorure.
In the background, you can also see a chain san mai tanto I've made from an earlier forging, where I didn't get the desired size of the original damascus sheet. (Picture 22)

Blade out of the acid bath, with no extra polishing, just washed in water with amonnia to kill the acid effects. (Pictures 23, 24, 25 and 26)
Knifemaking - Making a Chain San Mai Damascus Machete   Knifemaking - Making a Chain San Mai Damascus Machete   Knifemaking - Making a Chain San Mai Damascus Machete   Knifemaking - Making a Chain San Mai Damascus Machete   Knifemaking - Making a Chain San Mai Damascus Machete   Knifemaking - Making a Chain San Mai Damascus Machete   Knifemaking - Making a Chain San Mai Damascus Machete   Knifemaking - Making a Chain San Mai Damascus Machete
Picture 17   Picture 18   Picture 19   Picture 20   Picture 21   Picture 22   Picture 23   Picture 24
In hand for an idea of size (this thing is huge!) (Pictures 27, 28 and 29)
Knifemaking - Making a Chain San Mai Damascus Machete   Knifemaking - Making a Chain San Mai Damascus Machete   Knifemaking - Making a Chain San Mai Damascus Machete   Knifemaking - Making a Chain San Mai Damascus Machete   Knifemaking - Making a Chain San Mai Damascus Machete   blank image   blank image   blank image
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Finished Knife
Chain San Mai Damascus Machete   Chain San Mai Damascus Machete   Chain San Mai Damascus Machete   Chain San Mai Damascus Machete   Chain San Mai Damascus Machete   Chain San Mai Damascus Machete   Chain San Mai Damascus Machete   Chain San Mai Damascus Machete
Chain San Mai Damascus Machete   Chain San Mai Damascus Machete   Chain San Mai Damascus Machete   Chain San Mai Damascus Machete   Chain San Mai Damascus Machete   Chain San Mai Damascus Machete   Chain San Mai Damascus Machete   Chain San Mai Damascus Machete
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