Brotherhood of Steel: The Wuertz Hammer In 2019

A pleasant drive through a farming community a little south of Phoenix, Arizona, leads to a dirt driveway with a sign that reads, “Wuertz Farm.” As cars file in past the miniature donkeys and horse corrals, a gentleman directs drivers where to park. A cameraman with a pack that appears to be tethered to a 100-ft extension cord works to get a live feed on a large flat screen TV. What may sound like a trip to the state fair is the opening scene to the Wuertz Machine Works 2019 Hammer In.

Travis Wuertz welcomes the crowd at the start of the 2019 Hammer In

The Hammer In is a gathering of bladesmiths from around the country, who come to share and exchange knowledge of their ancient craft. As one might expect, there is no shortage of beards on site, but not everyone is shrouded in Viking-style facial hair. A quiet young lady with a secret passion for bladesmithing stands alone, trying to warm herself in the morning sun, while a fifteen-year-old bladesmith of two years shows off some of his amazing work to his adult colleagues. Regardless of age, gender, experience, or skill, it is immediately apparent that this is a brotherhood like no other—a brotherhood of steel.

The beautiful work of 15-year-old bladesmith Zander Nichols

NOT SO PRIMITIVE

While the perception of some may be that bladesmithing is a primitive craft, the reality is quite different. There is an old Japanese proverb, “On-ko Chi-shin,” which literally translates, “Study the old, know the new.” The idea is that by studying the old ways, one can better understand the new ways. This very concept can be seen in practice by the astute observer within seconds of setting foot into the Wuertz Hammer In.

A hundred-year-old power hammer that has been retrofitted with an electric motor sits just feet always from a self-regulating, ribbon-burner forge, built by Travis Wuertz himself. As an engineer who is constantly looking to refine his bladesmithing, Travis designed a forge that not only distributes heat consistently throughout using a ribbon burner design, but also automatically adjusts to maintain a consistent temperature, and monitors the gas/oxygen mixture for efficient fueling. The design ensures very precise control during the forging process, where overheating can result in damaged steel.

A not-so-primitive self-regulating, ribbon burner forge in action

Mareko Maumasi, a Forged in Fire champion from Connecticut, and a wizard of Damascus steel, can be seen splayed over a large white easel pad working out a complex mathematical equation. When asked about it, he explains that it is an equation for predicting Damascus patterning. Apparently, there is more to it that just mixing hard and mild steels.

OLD DOGS AND NEW TRICKS

Throughout the two-day gathering, both young and seasoned bladesmiths deliver periods of instruction on topics in which they are highly skilled. Michael Quesenberry, who specializes in daggers, bowies, and forged integrals, kicked off the event with a demonstration of how he forges his integral knives. An integral knife is one in which the blade, bolsters, tang, and pommel are forged from a single steel billet. With finesse and precision, Quesenberry hammers a round billet into an integral knife in less than an hour.

Michael Quesenberry demonstrates how he forges his integral knives

William Brigham awed attendees with a detailed explanation of Mokume-gane, a Japanese metalworking process used to bond a mixture of metals to produce a distinctive layered pattern, similar to wood grain. Mokume-gane loosely translates to “wood grain metal.” This process was originally used in Japanese sword-making to produce highly aesthetic accoutrements like the Tsuba (guard) and now serves modern bladesmiths in like manner.

A gathering such as this could not take place without plenty of talk about Damascus steel. Mike Tyre and Eric Fleming gave an informative lecture about feather Damascus. This technique involves stacking many layers of steel several inches tall and using a dull wedge to split through and stretch the layers. A feather-like pattern is the result when the sections are rejoined and flattened out. Mareko Maumasi also gave a mathematically-charged lecture on mosaic Damascus, and shared the cold coffee etching recipe that he uses to create the deep color contrast his blades are known for.

Mareko Maumasi lectures the crowd on Mosaic Damascus

At one point during the second day, one of the ABS Master Bladesmiths attending the event turned to this author and said, “You know, I’ve been doing this for 30 years. There’s not a whole lot I haven’t seen or don’t know how to do when it comes to making knives, but these new guys are taking things to a whole new level.”

FIT & FINISH

Any bladesmith worth their salt will tell you the clean finish and precise fitting of a blade to the handle and accessories is what truly distinguishes the master craftsman. This requires the ability to work around a grinder to cut, shape, refine, and polish the blade, handle, and fittings. Mike Quesenberry demonstrated his mastery of fit and finish with a handle shaping demonstration and a blade grinding demonstration. There are few blade designs that challenge a bladesmith’s symmetrical grinding ability like a dagger, and Quesenberry showed us why he is one of the best at making daggers.

A well-used TW-90 grinder, the invention of Travis Wuertz himself

Of course, the Wuertz Hammer In would not be complete without a demo from Travis Wuertz himself. Travis has designed the most coveted knife making grinder on the planet, the TW-90, so he finished up the two-day event with some of his tips and tricks for precise grinding and finishing using his grinder and the myriad of attachments he has designed to make the knife maker’s life a whole lot easier.

SHENANIGANS

At rare events like this, where bladesmiths and knife enthusiasts gather from all over the country, there’s not much desire to go back to the hotel at the end of the day, rather the real fun begins when the day is “over.” The hammers come out, the forges are lit, and sparks begin flying in the darkness of night as the intimate exchange of information takes place and the good times roll.

Perhaps the most attention-grabbing after-hours activity was the knife throwing class taught by Jason Johnson, an expert knife thrower and Forged in Fire: Knife or Death Season 1 finalist. Johnson instructed participants in his instinctive and powerful knife-throwing technique prior to turning them loose on the firing line, so they could try their hands at sticking some knives. It was an impressive sight to see even the young kids sticking knives into the wooden targets at various ranges after only a few minutes of instruction from Johnson.

Knife Throwing expert Jason Johnson schools us on his personal method

WRAPPING IT UP

At the end of this two-day venture, new friendships have made, old friendships have been rekindled, and this brotherhood of steel is alive evermore. These bladesmiths are bonded by the blood, sweat, and tears that flow through down the anvil and the spirit of fire that burns through the forge. They part ways with the kinds of hugs and handshakes that only those of a kindred spirit can share. Until they meet again.

A coffee-etched kitchen knife created by Don Nguyen of Tucson, AZ

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