The Process Behind the Blades
Take a look at part of the knifemaking process at Headhunter Blades
Tuhon Harley works at the grinder in the HeadHunter Blades shop, shaping and refining a blade through the stock-removal process. Before HeadHunter moved portions of production into larger-scale manufacturing, Tuhon Harley personally made each of the company’s blades by hand—grinding, shaping, finishing, and refining each design around the same mission-driven principles that still define HeadHunter Blades today.![]()
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Tuhon Harley heat treats a HeadHunter Blades WarHawk, bringing the steel to temperature as part of the hardening process. This stage is critical to developing the blade’s final strength, durability, and edge-holding performance before finishing, handle work, and final sharpening.
These HeadHunter blades are shown at the final stages of production, after shaping and heat treatment but before their protective finish coating and handle scales are installed. At this point, the blade geometry has been established and the steel is ready for the finishing steps that complete the build.
Rows of HeadHunter blades near completion, with their handle scales installed and each knife taking on its finished character. Beyond appearance, the handle material and contouring are shaped to provide a durable, secure grip while preserving the streamlined ergonomics HeadHunter designs around.
The final grind brings the blade to its working edge. After shaping, heat treatment, coating, and handle installation, Tuhon Harley refines the edge geometry and sharpens the blade as one of the last steps before it is ready to leave the shop.
From raw steel to finished form, every HeadHunter blade reflects a process built around purpose, function, and attention to detail. More than anything, the finished blades represent Tuhon Harley’s decades of martial arts experience, blade knowledge, historical study, and hands-on design expertise brought together in a functional tool.