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My Second go round with a Ghurka Khukri

    An M40 Basement Project 

For other projects, see my Bladesmithing pages


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        This is my third modification of a Khukri. I didn't take a million pictures this time, but the things I did to this one follow the first and second fairly closely. There are a few differences:

THE BLADE - I coated the blade with Brownells Bake-on epoxy coating in matte black for this one. I later performed some durability tests (a weekend spent chopping firewood while camping up North) to see if it would stand up to abuse. I'm sorry to say that it did NOT withstand it very well. I later did a home Parkerizing on it that DOES stand up to serious use and abuse. I don't have any pictures as yet, but will post some soon. (Note: I've now changed to a phosphate followed by Gun-Kote, which works very well and is extremely durable)

THE SHEATH - This one has a Kydex sheath, with snap closure, and a forward breaking draw. This means that the forward edge of the sheath parts, allowing the blade to come out the front (rather than straight up) which makes it both easier and quicker to draw, and allows for a positive lock into the sheath.

    Kydex is a tough and durable plastic that can be shaped and molded when heated. I used a jigsaw to cut out the initial rough shapes, leaving plenty of excess around the sides. Both pieces were then heated to about 250 degrees F in the oven for about 15 minutes. The next steps must be done quickly, while the plastic is still hot. I had the knife, two big squares of foam, a 2' x 2' piece of plywood and some weights ready to go. I removed the Kydex from the oven, put the base piece of Kydex on the first piece of foam, placed the knife on it, covered it with the other piece of Kydex, put the second block of foam on top, covered it with the plywood and finally stacked the weights on top, pressing the whole sandwich together. The foam molds the Kydex firmly around the blade. After several minutes, the plastic has cooled enough to take apart the sandwich. I then did final trimming with the jigsaw, and used Chicago screws to hold the two halves together (rivets can also be used).

I obtained the Kydex sheets from KNIFEKITS.COM. A 24"x12" sheet goes for about $9. They also sell it in 12"x12" sheets for about $5, but due to the length of this blade, longer sheets were needed. 

THE HANDLE - You will notice that I did some major reshaping on this one in order to give it a very positive grip. I also formed a lanyard hole at the bottom-rear of the tang. The handle scales are oak, and are held in place with #10 machine screws. I later cord wrapped it in black para-cord (see below for picture).

        Newest Khukri and Kydex Sheath

        Same blade with cord-wrapped handle. For instructions on how to cord-wrap a handle, see THIS PAGE