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They start with a flat bar stock of 5160 and/or 10/60 carbon steel and start
forging it just like the skilled craftsmen centuries ago. They start with a hot
forge as shown below.
 I observed them heat the raw
material and hammer it out, keeping the metal red hot so as to work the steel.
Once they forged it into a workable shape it was sent to another craftsman to
grind out the final look.
Why grind it? So as to give you the beautiful lines you see in every Generation2
item. And to be able to fit the handles to give you that tight fit and finish we
have been known for. But as you look closely at our swords or knives you can
still see the hammer marks from forging. Our customers demand quality and that
is just what we give them.
Next we moved on to the heat treating and tempering stage,
and it is done at one
station. They heated the blade to a red hot temperature and then oil quenched it
to harden it, then
re-heated it to
straw color (a temp of 400°) and quenched it
again in oil to temper it and
give it
flexibility as shown below.
Next the blade move on to a
polisher who puts a high polish that many of you have come to appreciate in our
swords. There is also a person who machines out the pommel and cross guards of
our swords and knives. Also a specialized person who shapes all the handles, and
person who fits them all together.
And yes a person who does final inspection to ensure proper fit and finish.
We even have people who only do the wood scabbards and people who do the leather
scabbards.
Each piece of the sword or knife and each scabbard is made and fit for just that
piece, not mass produced and mass assembled. Each one is meticulously done, but
yes at different specialized stations.
 Why are we showing and telling you this? Because you have asked, and because we
are proud of our exclusive & specialized foundry, and we are proud of the quality it produces.
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