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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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