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Gary Mulkey

Meteorite Damascus

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I didn't get in much shop time  today but did manage to get the first of  eight dogwood flowers roughed out.  These will all get inlaid side-by-side into a billet of 1084 using a canoe & 1084 powder.

 

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OK. Now you are just being a show off. :lol:

Keep going man!

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B)   !!!!!!!!!!!!!

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I got the remainder of  the flowers shaped & ready for welding today.  I hope that these pics explain my process.

 

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I'm going to  take some time off from the shop for a while.  I'll try to keep  you updated in a week or so as I progress with this one.

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Holy crap Gary!!! I cant wait to see this blade!!!

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Just amazing Gary, thanks for sharing, can't wait to see the result!

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This is going to be awesome!!!!!!!

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Posted (edited)

After taking a week off for a  small vacation, I'm back in the shop.  I got this billet  welded this morning.  Unfortunately the second flower didn't weld to  my satisfaction so I shortened the billet to  five flowers.  That still  gives me plenty of  steel for a  good  sized  blade though.  Here's a look at it after a rough grind and a quick etch:

 

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I'm thinking of using blackwood for the handle with an inlay of this mastodon ivory cut into a  scroll pattern.

 

 

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Edited by Gary Mulkey
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Dang......those are looking good!!!

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Above and beyond, sir!  

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Posted (edited)

Here's the blade after being forged, rough ground and a quick etch.  While forging I found that the flower next to the one which hadn't welded didn't fully weld either so my blade now has a four flower pattern.  Obviously that part of the canoe didn't soak at welding temperature long enough.  It appeared  to be hot enough but sometimes it's just hard to tell.  It still gave me 7 1/2" of blade though which is plenty.  Actually I  think  that I like the pattern better with four inlays than I did with more.  Anyway, it's much better to find these things out early rather than later when you can't work  around them.;)

 

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Edited by Gary Mulkey
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Lookin good! 

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Posted (edited)

Starting with the hilt:  Here's my original rough concept of what I want for the handle.  It will be made of blackwood with mastodon ivory inlays and 416 fittings.

 

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Edited by Gary Mulkey
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I am truly digging this build.  That handle is going to be amazing!

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Nice.  I wasn't sure how that tip flower was going to look once the tip was forged out, but it's definitely a win.

I'll be holding my breath while you cut out those inlays ;)

 

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Another soda an more popcorn, this is one hella good show  !!!

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16 hours ago, Brian Dougherty said:

I'll be holding my breath while you cut out those inlays ;)

 

Hurry! Brian's turning blue! [Ivory smokes as Gary's jeweler's saw shreaks and twangs like the bow of a mad fiddler]

 Seriously cool stuff Gary! This is my favorite so far. Ancient, but timeless. 

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Getting ready to cut the ivory inlays:

 

For once I ground off  the bark on these mastodon scales for a couple of reasons.  One I wanted more contrast in color with the blackwood and two I wanted a flat surface on which to glue the paper pattern--

 

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Here's the pattern cut out of cardboard--

 

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The pattern transferred to paper & reversed.  These will get cut out & glued directly onto the ivory.  It's still slightly crude at this point but I  will correct that when sawing out  the inlays.  [Each sharp point of the scroll will get a small silver pin inlaid there for effect.]  These scales will eventually be part of a frame tang handle.  I haven't decided for sure but will probably add a little  filework to the frame.

 

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I got delayed a bit on this one as my old  scroll saw that I  have  used for cutting  out inlays for years finally died so while I wait on a new one  to be delivered I got started  on making a  guard for  this one.

 

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Since I  forged the center of guard I'm having to  anneal it before cutting the tang slot.  Once the slot is  cut, I will profile the ball-tip guard and bend it into an "S".

 

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What kind of lathe is that, Gary?  The flat ways and what I can see of the saddle look like my Atlas/Craftsman 101.

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4 hours ago, Alan Longmire said:

What kind of lathe is that, Gary?  The flat ways and what I can see of the saddle look like my Atlas/Craftsman 101.

It's just a cheap Taiwan mini lathe that I added an external  1hp motor to as it was underpowered.

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Posted (edited)

I'm limited on what I  can do on this project until my new saw for cutting the inlays gets delivered but did manage to get the guard profiled, slotted, bent  & sanded today as well as the blade H/T'ed & tempered.:

 

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Edited by Gary Mulkey
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I finally got my new scroll saw in and got the inlays done.  While playing with the new saw, I wasn't satisfied with the first three attempts at inlays and ended up using some walnut burl with Arvorin for the inlays.  [If you're not familiar with Arvorin, it's the Cadillac of faux ivory.]

 

These inlays are far from perfect and definitely show that they were cut by hand but after I scrimshaw them I believe that they'll serve the purpose.

 

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