D. WEATHERBY FORGE

Ever since I was a boy I have been fascinated by knives.  I could spend hours gazing at display cases in the local sporting goods stores of all the knives they had for sale.  I was always attracted to blades that used natural materials for their handles such as antler, bone, and wood.  It wasn’t until ten years ago that I decided to try to make one myself. From that moment on I was hooked with bladesmithing!  The past several years I was finally able to get serious about the craft.  I started to build my own shop with the tools and materials I needed to forge my own blades. Most of the main tools I use I had to build myself.   Somewhere along the line I got the wild idea of forging blades from used rifle barrels.  After much experimenting I was able to complete a blade I was proud of!  I mainly use stainless steel rifle barrels.  I insert a high carbon tool steel rod in the chamber and forge weld the two steels together.  After the forging process I have three layers of steel forming a Damascus pattern known as “San Mai.” The 410 stainless steel barrel forms a softer steel jacket around the high carbon tool steel material on the cutting edge.  This method not only produces a stunning look, but also provides a far superior blade for strength and functionality.  The edge of the blade after heat treatment is very hard and will hold an edge for a long time.  The softer jacket provides strength and durability so the blade won't break. I use all natural materials for the handles much of which have ties to our family.  I include a certificate of authenticity with every blade, listing the materials used and their origin. Most of this material has been stabilized in a vacuum chamber with resin so that it will be very durable and last for years.  Depending on the style of blade, I often silver solder a shell casing on the pommel of the caliber barrel I used in the blade, adding a unique look representing where they came from. I also make a leather sheath to custom fit each knife.  I take pride in each piece I make and build them to be aesthetically pleasing and functional.  My hope is that these blades will last for years and be passed on for generations to come!