> khukuri making process

 Khukuri/kukri making process

The making of a single Kukri keeps four men fully occupied for an entire day, some time even more. All raw materials such as steel, brass, wood buffalo horn and hid and other things are first carefully selected and only the best are utilized. Then, only the actual process of making the Khukuri starts. It requires four men to make each blade. First of all, a skillful craftsman measures the length, weighs the steel and by the helper he is able to give an accurate shape of the Khukuri. A Skillful craftsman only does it by beating and hammering the red heated steel again and again. Everything sharpening, tempering on the edge of the blade and shaping the sheath and done by hand with carefully and only the machine is used to lather for shining of the Khukuri.

1.Measuring and Cutting     
5160 Carbon steel (Leaf spring used in truck) are imported to Dharan(eastern Nepal) and stocked at Everest Blade I Factory located in Panmara( place in dharan where our factory is located).Our export select  best spring leaf which doesn't have any cracks or puncture.Best spring  leaf are selected ,measuere and cut  in a piece as per required for the kukri.Intial weight of steel must be heavier than the weight of kukri since there is loss of weight in the process of making kukri.

 2.Beating and Hammering
This is the most difficult  and important process in kukri making.The real process of making kukri started from here.Initail shape is given to the kukri and entirely depends upon the whole process.Master craftsman play a important role  for rolling the steel back and fourth,side-by -side while being beaten  by 3 kg hammers simultaneously one by one. during this process the steel is regularly heated  and beaten countless.This  important and difficult task take about half and hour for each kukri . 

 Initail stage/shape got real shape in this stage.The kukri got its identification on this step.In this step master craftman  uses 1.5 kg hammer to bring actual shap of the kukri.Regular heating and beating process is continue for a long time.This is longest process in kukri making.Only mater craftman can take part in this process,becasue this stage requires lots of experience and years of skill of making kukri.

4.Making of Notch  
After giving shape to the kukri the notch/kaudi(blood dropper ) is made at the belly of kukri blade. the rod having shape liked notch at tip  is used carefully  hammered into the area with the help of helper.The blade is again heated  for making it soft  so that it cuts the edge of the blade and leaves the notch.

5.Making of Dora 
After making the notch just above at  below the beat  a line(Patterns) is made with the help a sharp pointed chisel  which is called "Dora".1 kg hammer is used for hammering .The brass is melted and spill in the area for decuration.The craftsman uses his toe fingers to flip the kukri  to find the right are to make "Dora"

This is another crucial stage where the blade is given extra hardness and strength. The craftsman carefully spills cold water onto the edge of fairly heated blade. It requires a great skill, as the spilling of water should be done only onto the edge and not all over the body. Otherwise it could result with cracks or at worst case could even break apart. Also the amount of water spilled should be very balance as needed and equal on both sides of the edge. This will give the edge additional strength and tolerance.

7.joining Handle    
After making notch and dora on the blade the handle is joined with the blade.Laha (traditional glue in nepal) is used to joing handle and kukri.duing this process "Kajo"/Bloster and "Chhapri"/bootcap is joined for strong feating of the handle .  The heated glue is pressed inside the handle and join blade is the handle and contact with cold which help laha to dry up quickly and turn solid and holds the tang firmly. More laha is added in the handle if needed.

Very traditional hand made machine "Shan" and  methop is still in used for  sharpening a kukri. This process requires two persons to complete the job. "Laha" traditional glue ,sand and tiny particle of  river stones are used to make the wheel "Shan". The wheel is made by cooking those mixture and made stong enought to sharpeing the blade.The master cratsman rubs the edge of the kukri aginast the wheel on the both side to slim the surface and make it sharp and his associate pulls the chain to spin the wheel.  The process is repeated for a long time untile the kukri got razor sharp.

9.Buffing and shinning     
The last stage of kukri making is buffing and shinning. The kukri blade and handle is shined and make smoothened with the help of buff shining machine. The craftsman should take care since the wheel is spining speedly.He should be bery cautious not to over do the work as heat (temperature ) generated while shining it may cause loose of temper ont he edge.

10.Testing/Checking quality
This is the final stage before transporting kukri to the kathmandu  for exporing kukri in internation market and supply to the other shop in kathmandu.All kukri are personly checked by our  factory manager .All kukris are thorooughly checked and carefully tested ,observed for any cracks or unwanted  pop-out.The testing of the edge of a blade against another blade is very crucial. The blade of a khukuri must slice the spine of another khukuri to some reasonable depth to be qualified for supply.If any kukri doesn't meet our required quality kukri got rejected and never supply to our warehouse and showroom in kathmandu.