Gas is more efficient and you only need a forge large enough to allow 4-6 inches of steel to heat at a time (which is all you can work before it becomes too cool). A forge with openings on each end will allow you to work larger pieces, but won't be needed for quite a while since starting out small and working your way up is the conventional wisdom.
A friend of mine bought the Tops. It's nice, but the price is obscene and it's not perfect.
I used it as a model, making the changes I wanted:
Hammer pommel
1/2" longer blade for increased "belly"
Serrations for thumb and forefinger.
more refined geometry for the saw/notching teeth.
I believe Himalayan Imports makes all their knives/kukris (reputedly the world's best kukri) from recycled truck springs. Mercedes first choice, Saab second. When they run low they put one of the junior guys on a bus to tour the scrapyards in India for more.
The heat treatment after the knife has be made is as important as the steel itself. Making a knife by simple stock removal will not result in a good blade without it. I have been buying knives from a maker named Michael Morris for a while now. He uses Nicholson files and when done heat treats them to 56-58rc. His knives take a very sharp edge and more importantly hold it well.
Here is his tactical filer, a necker, and a friction folder...all made from files.
Whene you consider the quality of his work and the quality of his handmade sheaths it amazes me he keeps his prices as low as they are. With this sheath the Tactical Filer was only $120 or so...
Leaf Springs also can be crafted into nice garden tools like Hoes or construction tools like shingle scrapers. I have see several swords made from them and they would cut off a 2 in oak limb with 1 swing.
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