Jump to content

A Mosaic Damascus WIP


Gary Mulkey
 Share

Recommended Posts

As "Old Man Winter" is hanging on,  I have  gotten into the habit of running the forge for at least  a couple  of hours the first thing in the morning just to  warm the shop even though I have plenty to work on without do more forging. 

Recently I got permission from my friend Jean-louis Regel to reproduce in my opinion one of his most beautiful Damascus patterns and thought that some of you might be interested  in how I  go about it. 

I didn't want to ask him to go through all  of the steps that he used to get the pattern as it  is fairly complicated one but as best that I can figure out from a photo of one his knives,  this is how it should be made:

A= 1/8" 1080(1084)

B= 1/16" 15N20

Welded pieces referred to as  "Billet"

1)The initial stack:

AA-B-A-B-A-B-A-B-A-B-A-B-A-B-A-B-AA

2)  Once welded cut into  two  pieces 1 1/2" wide x ?  &  stack:

     AA-Billet-AA-Billet-AA

3)  Do a "W" squeeze and forge to 1 1/2" wide

     Then cut into five equal length pieces & stack:

     Billet-A-BB-A-Billet-A-BB-A-Billet-A-BB-A-Billet-A-BB-A-Billet

4)  Weld and then square on the bias

     Orient so that the internal lines direct toward the center, 4-way & weld

5)  Tile cut & weld

I'm fairly certain that I won't recreate the pattern perfectly as every piece of my Damascus is always unique and has  some degree  of distortion but hopefully it will turn out  something like  this:

jean-louis damascus_opt

 

Here's my initial stack:

IMG_7097_opt

Once welded I cut it in two  and added more 1080 to  the stack:

IMG_7099_optIMG_7101_opt

To this I flipped  it 90 degrees and did a "W" squeeze drawing it out to 1/2" x 1 1/2" x whatever.

IMG_7104_opt

This I cut into  five equal lengths and stacked:  Billet-A-BB-A-Billet-A-BB-A-Billet-A-BB-A-Billet-A-BB-A-Billet

IMG_7107_opt

This stack was too  thick to go through the door of my  forge so  I  welded it in three parts and then combined them:

IMG_7108_opt

The next step  was  to square this billet  on the bias:

IMG_7111_opt

This is where I stopped for  the day.  I'll try to keep  you updated with more as I progress with this one.

  • Like 1
  • Thanks 1

Gary

 

ABS,CKCA,ABKA,KGA

Link to comment
Share on other sites

Nice. Does the pattern have a name?

"The way we win matters" (Ender Wiggins) Orson Scott Card

 

Nos, qui libertate donati sumus, nes cimus quid constet.

Link to comment
Share on other sites

Today I got the billet squared on the bias, drawn out, surface ground & 4-wayed.  Tomorrow hopefully I'll get the second 4-way done and be ready to tile cut.  (the x's on the four pieces are for orientation since the pattern is  directional)

IMG_7115_optIMG_7117_optIMG_7118_optIMG_7126_opt

 

Edited by Gary Mulkey

Gary

 

ABS,CKCA,ABKA,KGA

Link to comment
Share on other sites

11 hours ago, Gary Mulkey said:

It's pretty isn't it?

Absolutely 

"The way we win matters" (Ender Wiggins) Orson Scott Card

 

Nos, qui libertate donati sumus, nes cimus quid constet.

Link to comment
Share on other sites

I’m sure you will. Looking at that first picture, I would love to see the evil twin of this (A&B swapped).

"The way we win matters" (Ender Wiggins) Orson Scott Card

 

Nos, qui libertate donati sumus, nes cimus quid constet.

Link to comment
Share on other sites

20 minutes ago, Brian Dougherty said:

 I'm eager to see the Mulkey version of it!

Me too !!..........B)

If ya can't be good don't git caught  !!                                        People who say stuff can't be done need to

                                                                                                        git the hell outta the way of people who do stuff   !!!

Show me a man who is called an expert by his peers         

And I will show you a good man to listen to ......

Show me a man who calls himself an expert

and I will show you an egotistical asshole...............!!

 

                             

Link to comment
Share on other sites

Gary, I see why you liked it because that is great pattern for Damascus. Never seen anything like it!  I am anxious to see what you come up with!!

C Craft Customs ~~~ With every custom knife I build I try to accomplish three things. I want that knife to look so good you just have to pick it up, feel so good in your hand you can't wait to try it, and once you use it, you never want to put it down ! If I capture those three factors in each knife I build, I am assured the knife will become a piece that is used and treasured by its owner! ~~~ C Craft

Link to comment
Share on other sites

I got the 4-wayed billet drawn out to 1"x1"x ?.

IMG_7127_opt

I then cut it into four equal length pieces and surface ground two sides of each.  This I tack welded together into a second 4-way.

IMG_7118_optIMG_7134_opt

Once welded I did an additional squaring on the bias to get the final pattern.

IMG_7136_opt

 

Here's the billet drawn to size for tile cutting.

IMG_7140_opt

And my first look at the pattern.  ( the ugly gray blotch is the remainder of a MIG tack weld on the ends of  the 4-way and will come off when tile cut)

IMG_7146_opt

The next step  will be to surface grind two sides and tile cut.

Gary

 

ABS,CKCA,ABKA,KGA

Link to comment
Share on other sites

I'm very grateful for these step-by-step processes you post Gary. They are extremely inspirational. I hope you post some intermediate pics of the tile cutting & welding steps.

  • Like 1

“So I'm lightin' out for the territory, ahead of the scared and the weak and the mean spirited, because Aunt Sally is fixin’ to adopt me and civilize me, and I can't stand it. I've been there before.”

The only bad experience is the one from which you learn nothing.  

 

Josh

http://www.dosgatosdesignsllc.com/#!

https://www.youtube.com/channel/UCdJMFMqnbLYqv965xd64vYg

J.States Bladesmith | Facebook

https://www.facebook.com/dos.gatos.71

https://www.etsy.com/shop/JStatesBladesmith

Link to comment
Share on other sites

6 minutes ago, Joshua States said:

I'm very grateful for these step-by-step processes you post Gary. They are extremely inspirational. I hope you post some intermediate pics of the tile cutting & welding steps.

Will do.

Gary

 

ABS,CKCA,ABKA,KGA

Link to comment
Share on other sites

On ‎1‎/‎26‎/‎2018 at 3:05 PM, Joshua States said:

I'm very grateful for these step-by-step processes you post Gary. They are extremely inspirational. I hope you post some intermediate pics of the tile cutting & welding steps.

Here's a look at my process for tile cutting.  I number each tile primarily for orientation so  that I get them tack welded correctly.

IMG_7172_optIMG_7199_optIMG_7203_optIMG_7205_opt

 

  • Thanks 1

Gary

 

ABS,CKCA,ABKA,KGA

Link to comment
Share on other sites

Truly inspirational! And the sneak peek of the pattern before cutting the tiles looks extremely promising. Looking forward to the result. 

  • Like 1
Link to comment
Share on other sites

Thanks Gary!

  • Like 1

“So I'm lightin' out for the territory, ahead of the scared and the weak and the mean spirited, because Aunt Sally is fixin’ to adopt me and civilize me, and I can't stand it. I've been there before.”

The only bad experience is the one from which you learn nothing.  

 

Josh

http://www.dosgatosdesignsllc.com/#!

https://www.youtube.com/channel/UCdJMFMqnbLYqv965xd64vYg

J.States Bladesmith | Facebook

https://www.facebook.com/dos.gatos.71

https://www.etsy.com/shop/JStatesBladesmith

Link to comment
Share on other sites

I got  the blade forged to shape  this morning. 

IMG_7209_opt

Here's a look at the pattern after a rough grind and quick etch.  It will get a lot more contrast after H/T'ing, a proper hand sanding  and a full etch.

IMG_7224_opt

 

Edited by Gary Mulkey
  • Like 2

Gary

 

ABS,CKCA,ABKA,KGA

Link to comment
Share on other sites

Man, that is a success!

I appreciate you showing hte steps to the mossaic work.  One of these days I'm going to give that a shot.  It is still of a brain bender for me right now.

I reacall that you preferr welding without flux.  Is that true through all of these steps? 

 

 

-Brian

Link to comment
Share on other sites

13 minutes ago, Brian Dougherty said:

Man, that is a success!

I appreciate you showing hte steps to the mossaic work.  One of these days I'm going to give that a shot.  It is still of a brain bender for me right now.

I reacall that you preferr welding without flux.  Is that true through all of these steps? 

 

 

Yes.  The only time I used any borax was to  prevent scaling during the normalizing  process.

Gary

 

ABS,CKCA,ABKA,KGA

Link to comment
Share on other sites

Well, it's not the same as JLR's pattern, but dang man, that looks nice!

“So I'm lightin' out for the territory, ahead of the scared and the weak and the mean spirited, because Aunt Sally is fixin’ to adopt me and civilize me, and I can't stand it. I've been there before.”

The only bad experience is the one from which you learn nothing.  

 

Josh

http://www.dosgatosdesignsllc.com/#!

https://www.youtube.com/channel/UCdJMFMqnbLYqv965xd64vYg

J.States Bladesmith | Facebook

https://www.facebook.com/dos.gatos.71

https://www.etsy.com/shop/JStatesBladesmith

Link to comment
Share on other sites

3 hours ago, Joshua States said:

Well, it's not the same as JLR's pattern, but dang man, that looks nice!

Thanks.  I didn't expect to be able to exactly duplicate his pattern but I'm satisfied with the outcome.

Gary

 

ABS,CKCA,ABKA,KGA

Link to comment
Share on other sites

Create an account or sign in to comment

You need to be a member in order to leave a comment

Create an account

Sign up for a new account in our community. It's easy!

Register a new account

Sign in

Already have an account? Sign in here.

Sign In Now
 Share

×
×
  • Create New...