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Bob Kramer is one of
a hundred and twenty-two people in the world, and the only former chef,
to have been certified in the United States as a Master Bladesmith. To
earn that title, which is conferred by the American Bladesmith Society,
Kramer underwent five years of study, culminating in the manufacture,
through hand-forging, of six knives. One of those was a roughly finished,
fifteen-inch bowie knife, which Kramer had to use to accomplish four tasks,
in this order: cut through an inch-thick piece of Manila rope in a single
swipe; chop through a two-by-four, twice; place the blade on his forearm
and, with the belly of the blade that had done all the chopping, shave
a swath of arm hair; and, finally, lock the knife in a vise and permanently
bend it ninety degrees. The combination of these challenges tests steel's
two chief but conflicting capabilities: its flexibility and its hardness.
Despite attaining a master's status, Kramer remains in awe of steel's
unsolved mysteries. Like a mad alchemist, he cannot stop tinkering with
steel recipes, forging together different metal blocks and powders to
ennoble iron with just the right amount of nickel, manganese, or some
other selection of chemistry's basic elements. The amalgams continue to
respond in ways that baffle the most experienced metallurgists. Even so,
he has not done badly. One morning, the no-nonsense culinary magazine
Cook's Illustrated called his shop, in Olympia, Washington, and ordered
one of his knives to include in an equipment-rating article. Kramer worked
into the night for three days, and then shipped off an eight-inch chef
's knife. When the magazine's story ran, last year, it included a small
sidebar asking whether such a seemingly straightforward knife could be
worth its exorbitant cost (four hundred and seventy-five dollars, at the
time). The editors' answer: "Yes. The Kramer knife outperformed every
knife we've ever rated." Kramer's backlog of orders, already long,
immediately jumped to two years. A few months later, the kitchen-supply
chain Sur La Table asked Kramer to design a commercial line of knives,
which the store introduced this fall. As he prepared for his mass-market
debut, Kramer made a series of trips, including a few to Japan, the High
Church of steelmaking, where his commercial knives are being manufactured.
Kramer's itineraries matched the way he lives: a restless, almost insatiable
search for essences, for the soul of craftsmanship, for perfection in
a household tool.
Most bladesmiths
come out of the ranchlands and hunting hollows of rural America, and
they look, speak, and dress like throwbacks to the days of the covered
wagon. By contrast, Kramer--who has been not only a chef but also a
waiter, a folk-art importer, an improvisational-theatre performer, and,
for a year in his twenties, a Ringling Brothers clown--arrives at knife
shows looking like a Silicon Valley entrepreneur: button-down silk shirts,
neatly pressed slacks, a thin goatee on a sharp face. Now fifty, and
a trim five feet ten, Kramer is upbeat and alert, and he moves fast.
Talking to him can be like playing with a dog; his face seems to be
constantly on the lookout for fun. He is almost allergic to advance
planning. One morning in 1997, when he was refining the design for his
chef 's knife, a passerby, stunned by the sight of a blacksmith's shop
in downtown Seattle (Kramer moved to Olympia in 2005), popped in and
started badgering him with ideas. Rather than drive the visitor away,
Kramer listened to him. It turned out that the man was a sailor, and
he was adamant that the shape of Kramer's blade should match the lines
of a Six-Metre sloop--a curve, he argued, that holds universal value.
That line remains one of the hallmarks of a Kramer knife.
Earlier
this year, when Kramer took me inside his shop (a quintessential prefab
industrial cavern), he explained why he's no longer a chef: "I
decided I wanted to make something that lasted longer than a meal."
Tools, thick leather aprons and gloves, dusty old swords, and strips
of steel in various stages of knifeness were strewn everywhere. Stacked
along one wall were approximately a hundred plates (six feet long, two
feet wide, a quarter inch thick) of Kramer's favorite grade of steel.
The pile would last three to four years, since Kramer makes an average
of only five knives a week. (Most knife factories, even small ones,
make that many in an hour.) Surrounding the steel was a cornucopia of
metal in various forms: bars and rods of assorted lengths, thicknesses,
and grades; bags of specialized powders; and a scattering of power tools
that hammer, cut, or squeeze.
During
my visit, Kramer was absorbed in one of his incessant studies--this
time, an attempt to replicate the legendary achievements of Frank J.
Richtig. In 1936, Richtig, a Nebraska blacksmith, made "Ripley's
Believe It or Not!" for an act that he performed at state and county
fairs: according to "Ripley's," this was a man who "cuts
cold steel . . . auto parts, railroad spikes, buggy axles, etc., with
a butcher knife, and then cuts paper with the same knife!" (Cutting
paper may not sound like much, but it's a surprisingly demanding test
of blade sharpness which is still in use, even in modern factories.)
Richtig supposedly had a special system for heat-treating his blades,
which he never revealed. To this day, scholarly papers occasionally
appear in the annals of metallurgy which attempt to uncover Richtig's
methods. "I would love to crack this," Kramer told me. "If
I could do that, game over. I win!"
Kramer
began his Richtig experiment the way he makes his standard custom knives:
he ran a steel plate through a band saw, cutting out several knife-shaped
chunks, and then, with a pair of tongs, laid one on a brick in his forge--a
two-foot-square, gas-fired kiln. Kramer normally uses a pyrometer to
tell him when a blade has reached its critical temperature. But on this
particular day the gauge was on the blink, so he had to work the way
that Richtig and centuries of samurai swordsmen before him did: by eye.
Visual acuity is paramount in bladesmithing, because slight temperature
variances can mean the difference between a blade that's tough and another
that's brittle. Within two minutes, this blade was a glowing orange,
just shy of fifteen hundred degrees. Kramer picked up his tongs, removed
the blade, and dropped it on the floor to cool. (The standard blacksmithing
image has the smith beating the blade with a hammer at this point; while
many still do this, to eliminate bubbles and the like, it's seldom necessary
with today's industrially rolled steel.) After ten minutes, when the
blade was cool enough to handle, Kramer gave it a quick, blunt edge
on a grinding wheel. Then he wrapped a wire around its handle end and
dangled it in a series of containers full of molten salt. The first
of these baths, which sets the steel up for hardening, simmers near
forging temperatures. The last, a luxurious two-hour soak that matches
the baking levels of a household oven, lets the steel relax; as the
atoms inside the steel gradually migrate away from one another, they
settle into roomy corners free of pressure from their neighbors. This
is the "tempering" stage, the final step that keeps a blade
from being fragile. (Sometimes--depending on the grade of steel, and
the hardness levels that Kramer is after--a knife will, before tempering,
take a dip in a warm bucket of oil, or another full of dry ice and acetone.)
After lunch, Kramer pulled the blade from its final salt bath and hung
it on a wire rack to cool. Ten minutes later, he was standing in his
sharpening room, slowly rocking the knife against a series of sandpaper
belt grinders, coarse- and fine-grit wheels, and, finally, a soft cotton
wheel coated with a waxy green polishing compound. Kramer now asked
me to lay a long bolt across his anvil. He picked up the newly forged
knife, held it on top of the bolt, reached for a heavy forging hammer,
and started banging away. The bolt gave, but so did the knife. Damage
to bolt: a quarter-inch cut. Damage to knife: a sixteenth-inch chip.
Kramer
studied the pile of broken metal in his hand and looked up, amused.
"Well, we know that's not it." He then repeated the process
with a second blade--heating and cooling it at a different series of
temperatures--but this time he tried an old trick: when sharpening the
blade, he gave it a "beefy" edge, grinding it to a relatively
wide V. Kramer took this route reluctantly, knowing that it might draw
scorn. Sharpness, it turns out, is a surprisingly complex and contentious
notion. Any decent knife can be made sharp at its cutting edge; what
matters is the shape of the steel behind it--what cutlery experts call
"edge geometry." A blade that is ground, for instance, with
wide, heavily angled geometry won't move through fish or a tomato as
smoothly as a thin, tapered edge can, but it will murder chicken bones;
and so, Kramer figured, it ought to do a job on a bolt. This time, the
bolt split and left only a slight mark on the blade's edge. Kramer's
eyes widened: "I think I just did it! Let's do that again--that
was fun!" Another whack, more success; but when it came to the
final test--cutting newspaper--the knife failed. Kramer again examined
his blade. "I'm still in the dark," he said.
At dinner
one night, while biting into a piece of tuna at a well-regarded sushi
restaurant, Kramer suddenly stiffened. "Did you hear that?"
he asked. Kramer was sitting a good twenty feet from the kitchen, with
his back to the chef, but he immediately recognized the faint sound
of steel against steel, as the chef took a moment to work his knife
over a metal rod called a honing or sharpening steel. "That was
really weird," Kramer said. Professional chefs, especially sushi
chefs, typically sharpen their knives at the beginning of the night's
work or at the end--almost never during mealtime. Moreover, sharpening
steels are meant for European, or "Western," cutlery, not
Japanese. Either this chef, an elderly Japanese man, did not know how
to use his own cutlery (which was unlikely) or he wasn't using a sushi
knife. After our meal, Kramer approached the sushi counter, thanked
the chef, and peeked at his knife. It was a cheap Western chef 's knife,
not even a sushi blade. Outside on the sidewalk, Kramer paused to absorb
the incident. "You would never see that in Japan," he said.
The encounter explains a lot about the great war between Japanese and
Western cutlery, a story that unfolds the moment these two kinds of
knives hit a simple sharpening steel.
Since any
good knife can be made razor sharp, the ultimate question is what happens
to it in the minutes, hours, and weeks after its first use, as cooks
cut food. Part of the answer lies in the hardness of the steel, which
is commonly measured by a family of devices called Rockwell scales.
These punch steel with a pin, then calibrate its resistance from zero
to near seventy. (Some of the world's softest steels, with Rockwell
ratings down in the teens, are found in our buildings and bridges, where
elasticity is paramount; items such as train tracks and car axles fall
somewhere in the middle, with Rockwells in the thirties and forties.
At the top of the scale are tool steels, such as drill bits and ball
bearings, and knives.) On the retail market, Western knives tend to
be the softest, with Rockwell ratings in the middle to upper fifties.
This makes a Western knife dull in a relatively forgiving fashion: the
microscopic teeth at the knife's edge bend over. A sharpening steel's
purpose, therefore, is to push back the blade's teeth so they stand
up and cut again. (In this sense, a sharpening steel doesn't actually
sharpen; it just realigns, or "hones," the edge. On a Western
knife, in fact, the hairlike edge is often so soft that, when sharpened,
it forms a flimsy, invisible burr, which is best removed with a compound-soaked
leather wheel or strop.) The Rockwell of a traditional Japanese knife,
by contrast, runs in the middle sixties--at least near its edge, which
is often harder than its more resilient back side. The blade's profile
also tends to be thinner, because Japanese cuisine revolves around relatively
yielding foods (primarily fish and soft vegetables). If Japanese knives
are restricted to this cuisine, and used carefully, they will remain
sharp far longer than Western knives do; this is what cutlery dealers
really mean when they say that Japanese knives are "sharper."
When the edge of a Japanese knife dulls, however, its tiny teeth do
not bend: their points break off. That's what happens, quickly and disastrously,
when a traditional Japanese knife is "steeled." If damaged
like this, Japanese knives can be fixed only with a proper set of sharpening
stones or an expert regrinding. This partly explains why they have been
slow to catch on in Western kitchens. Americans simply eat more roughly
than the Japanese do. We cook ribs and T-bone steaks. We split chickens.
When halving an acorn squash or making a post-Thanksgiving sandwich,
the average American reaches for any knife that's handy--thick or thin--and
treats a cutting board like a chopping block. As a result, any cutlery
dealer can regale you with stories about customers who have come in,
frustrated, with chipped Japanese knives. Kramer has been approached
by dozens of professional chefs with this complaint, mostly during his
six-year stint as a knife sharpener--a business he once operated out
of the back of an old bread truck.
Kramer
first became fascinated by sharpening in the mid-nineteen-eighties,
when he was in his early twenties, and was hopping from restaurant to
restaurant as a prep cook. In each kitchen, he met chefs who knew almost
nothing about knives. "These are our main tools," he recalls
thinking. "Why don't we know how to take care of them?" Kramer
decided to learn everything he could about the process. At first, all
he found were the coarse electric sharpening machines popular at the
time, which do little more than ruin a good knife. Then he heard about
an unusual travel opportunity: for seven hundred dollars, Eastern Airlines
was letting people design their own cross-country tours, with stops
in six cities. Kramer chose New York, Chicago, Phoenix, Atlanta, San
Francisco, and, finally, his home town of Seattle. At each stop, he
recalled, "I went to every knife store I could find in the Yellow
Pages, and asked to see its sharpening room." Most turned him down.
Then he arrived in San Francisco, where, at a small shop named Columbus
Cutlery, an elderly Italian man led him into a room outfitted with a
variety of sharpening wheels, all slowly turning on one big spindle.
The cutler taught Kramer the nuances of the proper grind, how to lubricate
a wheel with lard, and how to look for, and correct, irregularities
in a blade. Upon returning to Seattle, Kramer spent the next three years
setting up his truck to look just like the Italian's workshop.
One evening,
Kramer noticed an ad for a two-week course in Washington, Arkansas,
where the American Bladesmith Society would teach people how to hand-forge
knives. Kramer took the course, returned to Seattle, built a forge in
his garage, and almost burned his house down. Four years later, in 1997,
he was running three folk-art import stores and a hip little shop in
a downtown warehouse which offered sharpening services and handmade
knives. Kramer now felt ready to seek a Master Bladesmith's certification,
a coronation that the A.B.S. confers once a year, in Atlanta, at the
Blade Show and International Cutlery Fair. Kramer passed, on his first
attempt, but he still vividly recalls his jitters the night before his
exam. He woke up repeatedly, oiling and cleaning his knives again and
again--anything that "would put some good juju in 'em." Throughout
his hotel, other bladesmiths were going through similar moments of panic.
When I
visited this year's convention, I got a chance to watch the collective
anxiety unfold. On the show's opening morning, twenty knifemakers arrived
with hopes of being certified as either a Journeyman or a Master Smith.
Most were already commercially successful--some sell their knives for
thousands of dollars apiece. Still, the mineral oil and Q-tips were
flying up to the last moment. This was the aspiring bladesmiths' final
exam, their "American Idol" moment--an achievement so significant
in the bladesmiths' world that it has caught the interest of the old
craftsmen's guilds of Europe. The knifemakers had each brought five
gallery-quality knives, which they laid out on white tablecloths with
their test knife--the fifteen-inch bowie that each man (all were men)
had used, under the watchful eye of a senior smith, to cut rope, lumber,
and arm hair, and that was now bent ninety degrees. The judges, a collection
of veteran Master Smiths, explained that the slightest imperfection
in a blade would cause the maker to fail. The same went for tardiness.
In response, one smith, whose hotel was only ten minutes away, got up
at 3 A.M. to make sure that he wouldn't be late. Another, an American
based in Australia named Shawn McIntyre, said that he woke up "fifteen
to twenty times" with a persistent dream that the wood on his dagger
handle had shrunk by a quarter of an inch. ("I kept telling myself,
'This can't be happening! Go back to sleep!' ") None of them reported
having slept more than a few hours. ("Sleep?" a pipe fitter
from Columbus, Ohio, asked. He laughed. "My whole life is on the
line, that's all.") As a hazing ritual, the judges often tell smiths
who are about to pass that they have "bad news"--a greeting
that caused one applicant's blood pressure to rise so high that he had
to go to the hospital.
All this
may sound extreme, but so are the judges' standards, which are neatly
illustrated by the story of Bill Burke. In 2002, a trucker used Burke's
knife to escape from a wreck. The trucker had first tried another knife,
made of the same steel, but it snapped; Burke's knife cut a large hole
in the truck's cab, reportedly made of "double-thick-layered steel,"
and suffered only a mild chip. When the news spread, knife orders poured
in. Several years later, Burke applied for his master's smithing stamp,
but the judges turned him down--for mistakes that apparently didn't
bother the show's buyers. "Even though the judges failed me,"
Burke told me, "all of the knives I brought were gone in about
fifteen minutes." One sold for forty-eight hundred dollars. This
year, the judges finally passed him.
Kramer's
role at this year's show was to serve as a human display item at the
booth for the U.S. division of Kai, the Japanese houseware and cutlery
corporation that is manufacturing Kramer's Sur La Table line, under
its explosively successful brand, Shun. Kramer's booth demands turned
out to be light, however, so he spent most of his time racing around
the exhibit hall.
His frenzy
was easy to understand. The place held eight hundred booths and tables
offering items such as sheep horn and mammoth tusk for knife handles;
myriad rods and sheets of metal; all manner of sharpening gear, wood,
and precious stones; and, of course, thousands of knives. Curiously,
while this is the world's largest blade show, only a handful of the
makers there produce kitchen knives. Most make sport and high-tech "tactical"
knives (partly in pursuit of contracts from the military, which still
regards a knife as the soldier's ideal all-purpose tool, and the weapon
of last resort). The result is an annual spread of staggering lethality:
pocket knives of every design (and price) imaginable, sheath knives
smaller than your little finger, and medieval cleavers longer than your
arm. At table after table, big men with thick fingers showed off knives
with such intricate patterns that one would think they were made by
a diminutive Old World jeweller.
Much of
this energy is relatively new. "When I first got into this business,
in 1964, I had a hard time finding fifteen knifemakers from Alaska to
Florida," A. G. Russell, the ascot-wearing don of the modern knife
market, told me. "I've got three thousand in my computer file now."
The surge of interest seems partly due to the Internet, which not only
has made once obscure items suddenly accessible but has also spread
knowledge about the craft behind these items to a younger generation.
"The guys just starting out today, their knives are as good as
the best makers' fifteen to twenty years ago," Steve Shackleford,
the editor of the magazine Blade, told me.
To see
how these knives can perform, I watched a cutting contest one afternoon,
staged in the parking lot outside the exhibit hall. The contestants,
armed with huge knives made especially for these competitions, were
being timed as they cut through a stack of shingles, then another of
unopened soda cans; several rolling golf and tennis balls; two two-by-fours;
three pieces of tough Manila rope of assorted thicknesses up to two
inches; a roll of bamboo six inches thick (this is an old samurai training
trick, meant to simulate cutting through a body); a large plastic bottle
of water (straight down, starting with its cap); and a thick cardboard
tube, as many times as they could, as though preparing gourmet cucumber
rounds. Most of them accomplished all these feats in less than a minute.
One was a man in his sixties who the judge said "cuts like he used
to when he had hair." When the contest finished, I inspected the
competitors' knives. Their razor-sharp edges were virtually intact.
To my surprise,
most of these knives were not forged by bladesmiths but ground out (although
still by hand) from factory steel produced by Crucible Specialty Metals,
of Syracuse, New York, one of the United States' last remaining tool-steel
mills. The grade used in these knives was a high-tech alloy, which holds
an edge that is ferocious but difficult to sharpen. "It would probably
eat up a water stone," Kramer told me. In some ways, these obstinate
alloys keep solo smiths in business. A significant virtue of a forged
Kramer knife is that it takes a keen edge, holds it well, yet sharpens
easily; one of Kramer's fans, Charlie Palmer, the award-winning chef
of the Aureole restaurants, told me that he can revive the edge on his
Kramer knife with "literally four or five motions" on a basic
water stone (which is about the size of a cribbage board). Kramer's
knives achieve this level of performance because their Rockwell ratings
hover around sixty--comfortably between Europe's soft cutlery and the
hard blades of Japan--and because his carbon steel has an unusually
fine grain structure. Carbon steel does have the drawback that it rusts,
which is what led, a century ago, to the invention of "stainless"
steel. This is actually something of a misnomer, since food acids and
other liquids will eventually corrode any steel; for this reason, honest
cutlers prefer the term "stain-resistant." To be even "stain-resistant,"
though, steel must contain chromium, which creates an edge that is normally
coarser, and more difficult to sharpen, than its carbon cousin.
To be fair,
many A.B.S. smiths make carbon-steel knives that perform as well as
Kramer's on a stone; a few even make kitchen knives. But cooks who have
used a broad range of cutlery told me that Kramer's knives have a balance,
a physical comfort, a lightness and ease on the cutting board that their
competitors lack. Thomas Keller, of California's French Laundry restaurant
and New York's Per Se, calls his Kramer meat slicer his "show knife."
Lisa McManus, a senior editor at Cook's Illustrated, said that her testing
team was surprised by how quickly and smoothly Kramer's chef 's knife
cut up a raw chicken. When her teammates attempted the same task with
other knives, they were soon "sweating and cursing," their
blades slipping in their hands.
In the
exhibit hall, Kramer set out one morning in search of additional insights,
specifically regarding Frank Richtig. This led him to Al Pendray, who
was standing behind a table where some of the show's most serious knife
collectors were gathered. Al Pendray is a farrier (a horseshoer) in
Williston, Florida; in the course of a fifty-year career, he has shod,
by his estimation, as many as two hundred and fifty thousand horses.
Among those are five winners of the Kentucky Derby and several dozen
others that have placed in a Triple Crown race. He is also a Master
Bladesmith, and is famous for almost single-handedly re-creating the
ancient Persian method for making a highly distinctive form of steel
called Damascus. The Damascus pattern originated sometime in the third
or fourth century, A.D., but it has become commercially popular only
recently, largely because of its evocative appearance: a watery swirl
on the blade's surface. Today, the effect is typically achieved by welding
slabs of different metals together and then etching the surface to reveal
their contrasts. The original Damascus, now known as "wootz,"
achieved its watery striations very differently: by growing those whorls,
organically, within a single piece of metal. Wootz has long fascinated
metalsmiths--first, because it was reputed to make unusually lethal
weapons (legend has it that, during the Crusades, Muslim soldiers sliced
up not only their European opponents but their swords as well), and,
second, because, in the early eighteen-hundreds, the technique for making
wootz was pretty much lost. Ever since, European scientists have been
experimenting and theorizing. Then, one day in June of 1993, a Florida
horseshoer appeared at a Damascus conference in Hagen, Germany.
Pendray's
blades, which have an eerie charcoal color, proved to be the first ever
to match the old Persian patterns. Could they cut the same too? To find
out, Pendray and one of his smithing partners, John Verhoeven, a professor
emeritus of engineering at Iowa State University, subjected Pendray's
knives to an ancient Eastern test: cut a silk scarf as it floats to
the ground. A scarf is so light that most knives, even when razor sharp,
either grab the silk or leave a ragged cut. When the scarf was slashed
by Pendray's blade, Verhoeven told me, "it looked like it had been
cut with a pair of scissors." Verhoeven suspected something unusual
involving carbides, which are compounds that result when carbon and
other elements, such as iron or chromium, bond during forging. (Bladesmiths
love carbides, because they are hard and sharp, like microscopic diamonds.)
Pendray's signal discovery was a way to control how the carbides aligned,
which yielded wootz's unique pattern. If luck strikes, Verhoeven explained,
those carbides can line up along a knife's edge.
Pendray's
initial forays were hit or miss; it took him and Verhoeven ten years
to figure out a recipe that produces wootz consistently. (The ingredients
have included fresh-picked tree leaves, broken glass, oyster shells,
and a pinch of vanadium.) Pendray can now talk about the innards of
steel with anyone, blacksmith or physics professor. That's why Kramer
stopped by his show table--to see what new metallurgical findings Pendray
could suggest that might help a knife cut a bolt.
Pendray
promptly took Kramer on an hour's conversational ride, through the ins
and outs of how carbon and iron, the basic flour and water of steel,
behave under various conditions. Carbon, Pendray says, "is one
of the fastest-moving little atoms. They're very active. They boogie
all around." And they continually surprise, Pendray said, sometimes
"spheroidizing the whole cotton-pickin' thing!" (That's when
carbides in steel assume a spherical shape, lessening the metal's brittleness.)
Once Kramer
had soaked up enough new possibilities, he walked me to a table that
offered some of the garden-variety Damascus that's made today. Here,
he explained the differences between the average American smith's treatment
of this form (which he follows) and the version generally found on industrial
cutlery. In smith-made Damascus, carbon steel and other metals are forged
into hundreds of layers, and often mixed throughout the knife the way
vanilla and caramel are twisted into saltwater taffy. Commercial Damascus
generally uses only a few dozen layers, and the pattern is laminated
onto regular knife steel, creating something like a ham sandwich: the
bread and condiments are the whorled Damascus; the ham in the middle
is the blade's core steel--the knife's cutting edge. This technique
of cladding had been devised by various Eastern cultures before high-grade
steel was mass-produced, and it once had a practical purpose. It allowed
smiths to surround a strip of good, hard steel with cheap, softer metal.
Modern Damascus, however, is usually made entirely of high-grade metals.
The combination is attractive and, if the knife were ever used like
an axe, the slightly softer jacket might keep a blade from snapping
in half. In a standard kitchen, though, today's Damascus does virtually
nothing, despite cutlery dealers' claims that rough surfaces keep food
from sticking to the blade. Still, plenty of respected cutlery is made
with these laminations, including some of the finest knives in Japan.
Kramer's Shun knives were being fabricated this way, too, with some
of today's new, high-grade, stainless steel, in a design that he hoped
would remain faithful to his principles.
O n Kramer's
first morning in Japan, he was treated to an unexpectedly tense meeting
at Kai's Shun factory, which is based in Seki City, a small industrial
town in Japan's geographic belly that was once a center for samurai
sword-making, and is now known for its mass-produced cutlery. The factory
is housed in a boxy, modern building that is surrounded by the tiny
commercial vegetable gardens, many no bigger than half an acre, that
speckle nearly every Japanese city outside central Tokyo. On the factory's
top floor, as Kramer and the leading players from Kai and Sur La Table
collected outside a conference room, eight women in matching checkered
vests stood up in their cubicles and bowed in unison to greet everyone.
Almost immediately, though, the meeting led to conflict over last-minute
changes, one of which involved a seemingly simple matter: whether Kai
could smooth out the blunt sides of Kramer's knives. These edges--the
"heel," at the back of the blade, near the handle, and, more
important, the "spine," along the top--are typically squared
off, because that is how industrial machines stamp out a blade. But
the harsh corners can irritate the hand. As petty as this point may
seem, it matters greatly to professional cooks. The Japanese, for instance,
control their knives by pressing their forefinger on the spine. Western
cooks often go further, and "choke up" on a blade when they
chop food; I've talked to some who showed me deep, cracked calluses
at the base of their forefingers. Knowing this, Kramer, like many smiths,
puts a "crowned" spine and a rounded heel on each of his custom
knives, and for months he had been pushing Kai to do the same. "We
talked about it," Dennis Epstein, Kai U.S.A.'s senior manager,
said. "We just didn't have the skill to do it."
Kramer
was baffled by this. Kai's industrial process, after all, was distinguished
by its emphasis on hand-finishing--a process we had just witnessed during
a tour, where we saw most of the factory's workforce bent over grinding
wheels. But Epstein argued that the time it would take to crown a knife
would price Kramer's knives out of the market. Kramer disagreed, and
performed a mock demonstration of how he crowns a knife on a grinder
within minutes. Epstein grimaced. "None of the mass-produced knives
in the marketplace have a crowned spine," he said. Yet hadn't Epstein
just been talking to the Sur La Table executives about the retail market's
continual need for new knife designs? "You're spending so much
time trying to be innovative," Kramer said. "This is a very
simple innovation that will pay off for the life of the knife, and that
every serious cook will appreciate, every time they use it. And the
thing is, no one's doing it." (Months later, when Kramer's Shun
knives hit the stores, there was noticeable improvement. But the spines
and heels, and the handles, did not compare to those on a custom Kramer.)
In the
following days, Kai entertained its guests royally while continuing
to stumble with more design and production details. This concerned the
Sur La Table people, and their difficulties say a lot about the recent
upheavals in the cutlery market. For most of the past century, European
knifemakers (primarily Wusthof and Henckels, the two German giants)
have dominated the market for mass-produced cutlery. In essence, while
the Japanese were perfecting assembly-line craftsmanship, the Germans
perfected their robots. Over the past decade, however, American cooks
began to grow interested in Japanese knives, a trend that Kai jumped
on, in 2003, with its Shun line. Suddenly, culinary aficionados began
talking about those "clunky" German knives. Demand for Shun
cutlery soon outstripped Kai's capacities, leaving its executives scrambling
to please everyone.
Japan,
of course, has no shortage of expert knifemakers, and Kramer managed
to visit several in Niigata, a province north of Tokyo that specializes
in a variety of handmade tools, including kitchen cutlery. While most
small Japanese bladesmithing shops make knives only in the Japanese
style--that is, with a one-sided, "single bevel" edge--Niigata
smiths also forge knives with the symmetrical, double bevel that is
popular in the West. One is Junichi Takagi, a tiny seventy-one-year-old
with soot-black hands who is reputedly Japan's last artisan of carpenter's
adzes. He also makes a simple, crude-looking kitchen knife that Kramer
was particularly taken with. "I bet it will get sharper the more
you use it," Kramer told me. During tests, the behavior of Takagi's
steel--its sparks on a grinding wheel, its "toothy" capacity
to cut rope again and again--suggested ingredients that Kramer thought
would, when combined with his own steels, create a distinctive Damascus
edge. "You're getting, basically, three different surfaces,"
he said. "It's freakishly good cutting material." Takagi,
after all, was accustomed to making tools that had to survive hours
of slamming through lumber. Sure enough, his steel, which is especially
wear-resistant because it contains tungsten, was a kind that Kramer
cannot find in the United States. He promptly ordered some.
Before
we left, Takagi, who works in a narrow, smoky shop, mentioned, in a
moment of classic Japanese humility, that, despite fifty years of experience
making tools, he was still learning, still striving "to reach my
goal." When I asked what that goal was, he was taken aback. After
an awkward pause, he said that his dream was to be classified as a Living
National Treasure by the government--an honor currently reserved, in
the realm of tools and cutlery, for a select group of samurai-sword
makers.
One morning,
when Kramer was back in Seattle, he called with some exciting news:
a package had just arrived from the nation's leading Richtig knife collector,
Harlan Suedmeier. "There are about twelve knives in there,"
Kramer said. "My heart is pounding. They're cool. They are very
simple, and they are thin. If these things go through a bolt, I've got
a lot to learn."
Although
Richtig collectors tend not to test their knives, Suedmeier was willing
to let Kramer test two "to destruction." Kramer soon struck
his best Richtig pose and started hammering. The blade crumpled. Kramer
was crestfallen; then he found one of Richtig's old advertisements,
in which the smith acknowledged using wider edges for demonstrations.
Kramer retraced his Atlanta conversation with Pendray, returned to his
metallurgy books, and discovered a diagram that might lead to a crucial
refinement. Then he forged some steel that, when broken open, revealed
an unusually "creamy" grain structure. He promptly sent some
samples to a laboratory, to see if the grain size was dropping to a
level that would allow some extra hardness without lessening the blade's
resilience.
To his
surprise, the laboratory report came back with only a partial reading:
apparently, Kramer's grain structure was so fine that the laboratory's
microscope couldn't bring the particles into focus. Elated, Kramer returned
to his forge. Days later, he sent me a photograph of a bolt and a baby
pork bone, both splayed open with numerous slices. Lying on top of them
was a blade with a fat but unchipped edge. Kramer had cut a newspaper
with it, too. He knew it was not a knife for tomatoes, but it was enough
to make him dream about more experiments when his Japanese steel arrived,
and another possible breakthrough: a kitchen knife that would cut through
a cooked lamb bone. "That," he said, "would be huge."
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