Carter Cutlery

Secrets of a Samurai Bladesmith

17th-Generation Japanese Master Bladesmith Shares Ancient Secrets of Forging Razor Sharp Blades to a Select Few — Fortunate Enough to Spend One Week Crafting a Classic Blade… That Will Endure for Generations.

My Life Unfolds as if by Fate…

My life path was revealed to me in 1988 when I noticed a peculiar building while driving a scooter on an old Japanese narrow road in a small village in Kumamoto, Japan. It was an old wooden building with a glass display window in front. In the display window were some of the coolest knives I had ever seen. I pulled a U-turn and parked in the driveway. I opened the sliding glass door, which had a chime attached to it that rung softly, and I ventured into the shop. Immediately I smelled the aroma of a unique combination of burning pine charcoal embers and red-hot metal emanating from the traditional Japanese forge.

The Immaculate Blades…

My eyes were immediately drawn to the assortment of beautifully crafted, razor-sharp cutlery displayed on the shop walls. There before me were row upon row of traditional blades, their edges gleaming, their wavy temper lines and layers of lamination highly visible, with beautiful hand-carved wood handles of native wood. I felt that their sharp shapes and lines of obvious function were begging me to pick them up and put them to use. The traditional blade designs, which have largely remained unchanged for centuries, transported my mind back to a more romantic age when life was simpler and straight forward, uncluttered by electronic gadgets and computers, an age when a person was as good as their word, and a time when a great blade could mean the difference between life and death. I seemed to be in a trance for what felt like an eternity…

The Master Bladesmith…

I was brought back to the present when a kind and gracious gentleman entered from a back door and asked me in heavily-accented Japanese if he could assist me. I didn’t note any reservation in his demeanor despite the fact that he was facing an 18-year-old, blond hair, blue-eyed "gaijin" who could hardly speak Japanese! As I spoke to him, I realized that this man, Mr. Yasuyuki Sakemoto, was the Master.

My Wildest Dream Becomes Reality…

I could have sworn that something clicked between us as we struggled to communicate with each other that first and historic time, for when I indicated that I was interested in seeing more of his shop and learning what secrets lay within, he agreed to let me venture further. That first meeting led to a 6-year apprenticeship, a privilege that has never been extended to another. What a priceless opportunity, incredibly so, because I wasn’t Japanese.

And It Gets Ever Better…

On the eve of my seventh year, my Master approached me while I was hammering away at the forge, covered from head to toe in pine charcoal soot. I was in the fifth day working on a traditional Japanese Samurai sword to present to him as a token of my appreciation and to demonstrate my bladesmithing prowess that I had gained over the years. He bent down (as I was in the lowered pit of the Japanese forge), put his right hand on my shoulder, and told me, “You are to be the 17th-generation Yoshimoto Bladesmith.” Good thing I wasn’t swinging the hammer, or I might have struck one of my fingers! Was this a dream?

I’m Eternally Indebted…

Yes, Mr. Sakemoto proved to be the most generous and gracious Master an apprentice could ever hope for. I can never repay him for all that he did for me, but I can pay it forward to you… IF you are one of the few who respond immediately…

A Rare Opportunity

Now that I have moved my business, shop and family to the United States, I have decided to share with a select few — who understand the value of such a once-in-a-lifetime opportunity — the many secrets of forging razor-sharp blades that will last a lifetime in your family. Imagine creating with your own hands, a kitchen knife that is so sharp your spouse has to request that you cut the tomato slices “Thicker, please!” Or a tactical knife that you can bet your life on and then pass to your heirs — protecting them as it protected your life.

Whatever your cutlery interest is, I can provide the knowledge to make YOUR bladesmithing dream a reality!

Here’s What I Mean…

For one week you can participate in America's only traditional Japanese bladesmithing school, located in Vernonia, Oregon.

To make sure I am able to pass on to you, the legendary skills of the traditional Japanese bladesmith, the class will be limited to ONLY four participants.

YOU will create custom-made cutlery according to traditional techniques, and you will gain a comprehensive understanding of the “how’s and why's” of Japanese methods of cutlery production. The 50-hour course will consist of both hands-on bladesmithing and classroom lectures covering over 27 secrets of traditional Japanese bladesmithing including:

Selection of Steel

As a blade enthusiast, you may have encountered the vast array of steels: 440C, ATS34, D2 ,CMP S30V and many more! What do all these names mean? Which steels are good choices for a knife and what are their superiorities and shortcomings? Wouldn’t it be great if you could navigate your way through this most controversial topic with ease! I will give you the information you need to know, information that will make you THE AUTHORITY at any knife show or cutlery gathering!

Forge Maintenance

Do you know there are at least five different heat sources for forging steel? Not all forge fuels are equal. I’ll explain them all to you, and then we will use only the best to forge our blades! An added benefit of this knowledge is that you will never again have to mess around lighting and maintaining a fire. Re-master the most ancient of skills! Do you know the most important secret of building a great fire? Be your children’s hero at the campground for being the first to get that kettle boiling!

Lamination Techniques

A proven technique used since the early Samurai swordsmiths and Norwegian Vikings! If you know what you’re doing, you don’t have to compromise sharpness for toughness, or vice versa, as you do for homogenous steel blades. Laminating two or more different types of steel for one blade is truly the technique of “being able to have your cake and eat it too!” All blades forged by participants in this class will be laminated.

Forge Welding

Welding can be accomplished in many different ways: electric arc welding, MIG welding, TIG welding, friction welding, ultrasonic wave welding, laser welding, even welding by explosive charges (unfortunately, not part of this curriculum)! Did you know that welding in the blacksmith’s fire is the most ancient technique of all? Each participant will forge-weld at least one of their blades, thus sharing in the tradition of ancient bladesmiths.

And There’s More, A LOT more…

Forging to Final Thickness

One telling skill of the accomplished bladesmith is the limited use of a grinder to shape the blade after forging. It is said that 5 minutes of proper forging, and proper scale removal, saves 30 minutes at the grinder! We will forge our blades to their final thickness AND have a nice smooth attractive finish that doesn’t need extra polishing. This technique alone is worth the price of the course, as it will save a bladesmith thousands of hours in knife finishing labor!

Traditional Heat Treating Techniques

Proper Annealing, Cold Forging, Quenching and Tempering are the techniques that make Japanese blades what they are: THE MOST SUPERIOR CUTTING IMPLEMENTS IN THE WORLD! Surely the heart of blade metallurgy, thus, the heart of the course, lies within these techniques. You may be wondering how Japanese blades could be so different from western blades. The fundamental differences will probably shock you! But, these techniques will seem second nature to you after you put them to use creating your own blades. Let others contemplate the mystery of Japanese legendary blades, while you revel in complete understanding!

Straightening

Blades are only able to withstand force in two dimensions. It is absolutely imperative that blades be as straight and untwisted as is humanly possible. Unfortunately, the vast majority of blades out there are far from satisfactory in this criterion. Can you spot them? You’ll learn five different ways to check for blade straightness, and at the end of the course, I GUARANTEE you will be able to spot those “twisted terrors” out there! You’ll never look at those things that are supposed to be straight (gun barrels, measuring sticks, a building’s walls and roof lines) the same way again. WARNING! Don’t blame me when you start to notice all the imperfections in the world!

And There’s More, MUCH more…

Grinding, Polishing and Sharpening

Ask any blade expert and they will tell you that blade geometry is the most important aspect of blade making. The metallurgy of the blade is vital, but without great geometry, the blade will under-perform. Some of you may have been fortunate enough to attend one of my sharpening seminars or view one of my sharpening DVDs. These techniques will be your secret after intensive one-on-one instruction, and plenty of repetition, while studying with me during the week. YOU will truly be on your way TO MASTERY OF RAZOR-SHARP CUTLERY!

Attaching Handles

A great blade is only as good as its handle. The handle must facilitate the brain’s commands to the blade via the hand. What handle shapes and designs work well, and which ones don’t? Is it a matter of visual impression or feel? This much overlooked aspect of cutlery will be covered in detail, allowing you to ascertain great handle designs on your own!

Sheath Making

Razor-sharp cutlery needs safe and adequate protection. During the course, we will fashion some custom-made sheaths for our knives (“one-size-fits-all” doesn’t apply here!), and we will examine the most modern of materials as well as the most ancient. Beware! After what we show you, you might want to take up custom leather working as well!

Overview of Traditional Japanese Cutlery

Unlike western cutlery which has evolved into a “one-blade, many-tasks”-type, multi-functional tool (and thus, not suited particularly well for any task), Japanese blades are still highly specialized in design and function. The general knife buying public remains largely ignorant of the hundreds of specialized Japanese blades, but you will know the subtle differences between them all. This lecture will give you incredibly valuable insight to the Japanese psyche and to the rich tradition of superior blades.

And There is More, So Much More…

Philosophy of Japanese Metallurgy

Japan, like America, has a hugely successful space program, having launched hundreds of satellites into orbit around the earth. However, unlike America’s scramble towards technological advancement in every field, the Japanese hold their ancient formula for cutlery steel in the greatest reverence, and reserve it’s use for only the highest quality, most superior performance blades! Their best steel remains unchanged for over 1200 years! Find out why the “if it ain’t broke, don’t fix it” approach applies here.

The Five Criteria for Superior Cutlery

Everybody has an idea as to what makes a great blade, like, for example, how long it holds its edge. But is this criteria really at the top of the list, or are there more important things to consider first? In this controversial discussion, you will learn what to look for first in superior blades, and then what to look for in order of importance after.

Exposé on Laminates versus Homogenous Steel Blades

It was based on this essay, which was published, that I was awarded “Alien of Extra-Ordinary Ability” by the INS when I immigrated to this great nation in 2005. Find out what all the fuss is about as I uncover the superiorities and shortcomings of laminated blades.

Practical Parameters of Cutlery Design

There are all sorts of weird and wonderful knife designs available for sale on the market. Apart from looking cool, do you really know which knives are designed for the sole purpose of separating you from your hard-earned cash? Don’t let yourself throw away money by buying knives that have no practical use. I will help you avoid the features in knives that are only designed for marketing to the unwise. For hard-core knife collectors, this information will save you thousands over the years!

And Even MORE…

Proper and Efficient Blade Sharpening and Maintenance

I will share with you the theory, making use of drawings and diagrams, of the practical application of blade sharpening that you will practice in the shop to put the final edge on your knives. The topic of maintenance will be of particular value, as this is a factor you will encounter many months after the course, when the knives are showing need of some TLC. You will never wonder what to do about those neglected blades around the home.

Regional Variations in Traditional Japanese Bladesmithing

Not all areas in Japan produce the same kinds of cutlery. In this lecture, find out HOW and WHY blades vary from one region to another. Have you ever been to Japan? This will be a great opportunity to ask all those questions you’re dying to ask! A GREAT PRIMER FOR THE GUIDED TRIP TO JAPAN THAT I WILL TAKE WITH A LIMITED NUMBER OF LUCKY INDIVIDUALS IN THE NEAR FUTURE!!!

Relevant Strengths and Shortcomings of Man-made Sharpening Stones versus Natural Stones

Did you know that some natural quarried stones from Japan can cost upwards of $10,000 each, and that to properly polish and sharpen a genuine Samurai sword, you need at least $50,000 worth of natural stones! The explanation is quite straight-forward really. Is it necessary for the student of Japanese blades to acquire these legendary stones to achieve razor-sharp cutlery? In this lecture you will find out whether sharpening stones are considered the mate to a piece of cutlery, or simply an option, as in America.

And More…

A Guide to the Proper Pronunciation of Japanese Blade Related Terminology

You can butcher your food with your newly-made cutlery, and let others butcher the pronunciation of Japanese cutlery related terms. I will teach you to easily master the few terms related to cutlery, and when you speak them in front of other knife people, they will be amazed at your impeccable command of Japanese.

PLUS a “special slide show” that will leaving you longing to visit Japan for yourself -- you may be one of the lucky few who accompany me on my next trip to Japan.

Upon cCompletion of the course, each student will have completed:

One hand-forged kitchen knife

Before you forge your very own kitchen knife, you can choose from over 200 traditional Japanese designs that I make. You’ll start with the knife that will see the most daily use. Imagine the pleasure that will come from preparing your food with your own hand-forged blade! Even most professional knifemakers can’t claim that -- they usually just buy kitchen knives from me!

AND TWO MORE KNIVES AS WELL…

One hand-forged neck knife

A sturdy and absolutely reliable scary-sharp companion will accompany you for every waking moment of your after-course life! With no mechanism to break or fail you at the most inopportune time, and with the ease of sharpening and maintenance that is impossible with a folding knife, you will come to respect your neck knife more and more with every use. The most wonderful daily companion to have…

One outdoor/camp knife or tactical style knife -- Bears and goblins beware!

Lest your creative genius go unaddressed, here’s a chance to go “HOG WILD” with your own design (by this point, having already completed two totally practical knives, your sense of practical design will be honed to perfection). This knife will incorporate a metal guard or bolster between the blade and handle, so low temperature silver soldering will be taught as well.

This knife will be cherished forever!

In Summary of Carter Japanese Bladesmithing Here Is What You Get:

Hands-On Secret Bladesmithing Techniques

• Selection of steel
• Forge maintenance
• Lamination techniques
• Forge welding
• Forging to final thickness
• Traditional annealing techniques
• Scale removal
• Cold forging
• Straightening
• Quenching
• Tempering
• Grinding
• Low temperature silver soldering
• Polishing
• Sharpening
• Attaching handles
• Sheath making

PLUS I Reveal to YOU:

• Overview of Different Types of Traditional Japanese Cutlery
• Philosophy of Japanese Metallurgy
• The Five Criteria for Superior Cutlery
• Expose’ on Laminates vs. Homogenous Steel Blades
• Practical Parameters of Cutlery Design
• Proper and Efficient Blade Sharpening and Maintenance
• Regional Variation in Traditional Japanese Bladesmithing
• Relevant Strengths and Shortcomings of Man-made Sharpening Stones vs. Natural Stones
• A Guide to the Proper Pronunciation of Japanese Blade Related Terminology
• A Special Bonus Slide Show sure to leave you longing to join me on my next trip to Japan

Upon completion of the course, each student will have completed

• One hand-forged kitchen knife
• One hand-forged neck knife
• One outdoor/camp knife or tactical-style knife

I Wish More Knew What I Know…

All the skills and secrets that I will share with you took me over 20 years to acquire, including working as a village bladesmith in Japan. It is the culmination of having made more than 12,000 knives and sharpening more than 40,000 blades! Some aspiring knifemakers spend thousands of dollars on a short trip to Japan in order to study there, only to find their lack of fluent Japanese a barrier to true understanding of the craft. I struggled and studied hard and finally mastered the language, enabling me to understand the subtleties of their ancient bladesmithing art. Nobody else on this continent could truly teach you what I will teach you during this week together.

Carter Japanese Bladesmithing Courses