The making of kukri requires 3 to 5 persons fully engaged in different crafts to make a single kukri. First raw materials such as steel, wood and leather are carefully searched, evaluated and selected by our Master Bladesmith Mr. Purna Darnal. Then, the next process involves men who work on forging & hammering, scabbard making, sharpening, designing of the butt cap, wood / bone handle making, smoothing the blade & finishing the whole kukri along with its scabbard and Karda & Chakmak. Finally the quality check & kukri test is carried out by the master bladesmith Mr. Purna himself.
- Weighing the steel: The first process of kukri making requires weighing the steel to make the kukri. The initial weight of the steel is supposed to be more than the final stage as there is weight loss during the kukri making process.
- Measuring: The steel is measured to be the required length. The whole length from tip to tail of a khukuri is measured by a standard scale. Normally, about 2/3 inches of the extra area is measured on both sides of the steel as it is later squeezed a bit while hammering and beating.
- Cutting: The measured steel is then cut from the main body.
- Heating: The cut steel is heated appropriately in a small furnace to a temperature where the steel looses its magnetic properties.
- Beating and hammering: This process involves up to four men hammering and beating the hot steel. The kukri blade is continuously heated & hammered during this process. One blacksmith maintains the position of the kukri rolling the steel back and forth and side-by-side while being beaten by 3 other blacksmiths with the 3 kg hammer that gives the steel a rough shape of the final kukri. The desired full-tang or rat-tail is also shaped in this processes.
- Shaping: Extra layer of hammering is done by a single blacksmith with a smaller 1.5 kg hammer. The kukri gets its easily identifiable unique shape in this process.
- Making of Notch: The blade then is again heated for flexibility. The notch/kaudi (Blood dripper) is made at the belly of the kukri. A rod with the notch shape at the tip is carefully hammered into the belly area, that cuts off two pieces of the blade and leaves the notch.
- Grinding: While grinding a blacksmith has to be very precise, over grinding may thin the spine at any point. Regular check for symmetry is done. Grinding along the fuller is done which smooths the borders and more depth can be gained in bevel.
- Oil quenching & Tempering: The blade is heated again in coal oven then dipped in the oil to quench it. This is the crucial stage where blade gets extra hardness and strength. The blacksmith then spills cold water in a very balanced way as required on the two sides of edges only of the fairly heated blade. But nowadays, either tempering or quenching in oil is done
- Making of Handle: The handle of kukri is mostly made of rosewood or water buffalo bone. The blade of the handle is drilled to stick two parts of the handle even more strongly with aluminium rivet. The wood or the bone are cut in particular design to provide for the best grip. A line around the handle also known as dora is made with the help of a sharp chisel.
- Making of Bolster (Kanzo): The bolster is made of polished brass or polished iron. It is placed between the handle and the blade.
- Joining: After making the blade, bolster and the handle they are joined together meeting at the bolster. The heated glue is pressed inside the hollow part of the handle then the two parts of the handle are attached with the tang through the middle to provide a near permanent fixing.
- Polishing: The last stage in kukri making is polishing & cleaning the kukri. The kukri & handle is shined & make smooth with the help of buffing shining.
- Testing/Quality check: The final stage in every GGK kukri making process is quality test by master bladesmith Purna Darnal. He observes the blade very carefully checking its finishing, weight, dimensions, sharpness ets.. He also carries out testing of the kukri for the purpose it is made.
