custom knife holster – The ExhaustNotes Blog

By Joe Berk

The knife du jour is the Rough Ryder 854, which is a gigondo folder that looked like something I couldn’t live without when I saw it on the Chicago Knife Works site. I’m hooked on the large folders, and at a price of $14, this thing seemed too good to ignore.

The Rough Ryder 854. No one has these in stock anymore. It’s a lot of knife at any price.

The problem, however, was that the design was defective, or the quality was terrible, or maybe it was both. It was a subtle defect, one that most folks wouldn’t notice until they stabbed themselves with the tip.

I first saw the knife online somewhere, and then I looked for it on Amazon. I hit paydirt and I used my Prime membership to skirt the shipping costs. Two days later it was at my front door. It looked beautiful, but the blade stopped a little bit short of the knife being fully closed. That’s not good, I realized. I tried squirting WD 40 and then adding oil to the knife’s pivot point, but the blade still stopped a bit short of being fully closed. Back it went to Amazon.

But I like the knife. It looked good and it felt good. So I called Chicago Knife Works and ordered the same knife from them. I called first, and asked if they would examine the knife before it shipped for the problem the first one had. Sure, they said. No problem. Chicago Knife Works is always slow in shipping, though, so I waited the obligatory four or five weeks before it arrived. But finally it did, and I was like a kid at Christmas time when it landed in my mailbox.

You can guess where this story is going. The new Rough Ryder had the same disease. It wasn’t as bad as the first knife, but the blade didn’t fully close. If I ran my finger along the knife handle’s edge, the blade tip still ran proud, and I still saw it could stab me if I wasn’t careful.

The red arrow on the left shows the area I relieved, thinking it would allow the blade to go further into the knife when folded. I was wrong. The red arrow on the right shows the knife’s liner lock, which prevents the blade from inadvertently closing after it has been opened.

The engineer in me took over. I examined the open blade profile and saw a bump stop. If I ground that down, I thought, the blade would more fully close. So I started grinding with my Dremel. That didn’t work. I ground some more of the blade stop off, and things didn’t improve. I examined the blade’s profile and the knife again, and I realized there was another stop of the blade (on the other side of its pivot point) that also controlled where the blade came to rest when the knife closed. But I couldn’t get to that one. Hmmm. Time for Plan B.

What’s weird (and what’s an ingrained character flaw) is that I was really stressing out over this $14 knife. I’ll do that sometimes, and this was one of those times. I’ve been a lot less annoyed at things that are a lot more expensive and aren’t perfect. I should have just returned the Rough Ryder. But I was fixated on fixing the thing. In the Diagnostic and Statistical Manual of Mental Disorders reference manual, it’s identified as Gresh’s Disease.

When thinking about potential fixes, I realized if I couldn’t get the blade to close any further, I could reprofile the blade to get rid of the tip, or, to be more accurate, to lower the blade’s profile so that the new tip would be below the knife’s scales when closed. So that’s what I did. The stone came out, I went to work, stroking the blade tip and checking how the blade closed every few strokes. Voilà, problem solved.

The blade tip lay above the scales when the knife was closed. I ground it down in the area indicated by the red arrow. Problem solved.

A band aid fix, to be sure, but sometimes band aids work.

In the meantime, good buddy and craftsman extraordinaire Pauly bought the same knife. The guy is lucky; his Rough Ryder 854 closed the way God intended it to, and it did not have the same problem mine had. But he didn’t stop there. What the knives needed (both his and mine) was a holster.

The Rough Ryder and the holster Paul made for me.

I’ve known Paul longer than I’ve known any living person on the planet. Literally. We were next door neighbors back in New Jersey when I was born. Paul has always been good at creating things, and it turns out that leatherworking is among his many talents. Paul created custom holsters for these knives, and they look and work as good as anything I’ve ever seen. What’s really cool is the holster takes advantage of the knife’s curves. The holster is formed to the knife’s coke bottle profile, which secures the large folder when it is in the holster. It’s a hell of a nice gift.

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