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Made to Order
We are proud to offer top-tier custom combat knives and innovative sheath systems. Each knife and sheath is handmade from start to finish. They are purpose-driven designs that perfectly combine ruthless utility with aesthetic beauty. Whether you are law enforcement, military, a combat arts enthusiast, or a prepared citizen, our knives are designed to be reliable companions in the most challenging situations. Each design reflects our relentless commitment to excellence and providing the best possible tool for the job.
We develop all of our designs in conjunction with law enforcement and military personnel. Members of our team have extensive experiences in almost every combat and outdoor field that makes use of a knife. We take full advantage of this wealth of knowledge and experience when creating a new product to ensure it will function to the highest standard in the real-world scenarios for which they are designed. Should you choose to trust us with your need for a quality blade, you will become part of that process as we draw on your personal experience and feedback to evolve further in our pursuit of excellence.
How Courage Project knives are made.
Each knife starts with a hand drawn concept. When designing a knife, we start by identifying the specific task for which the knife is required. We then work backwards to create a custom design that will perform that task to the highest possible standard. Every feature is chosen with the end task in mind. This is what we call purpose driven design and it is what makes our knives unique.
Once the design is finalized, an appropriate thickness of steel is selected. If a finger loop is required, this is drilled prior to cutting out the profile.
The design is then traced onto the steel and a metal bandsaw is used to cut the rough profile.
The profile is then cleaned up with a small belt grinder.
Any inside corners are refined with sanding drums of various sizes to ensure a perfectly symmetrical arch. The holes for the handle scales are also drilled at this stage.
If a large quantity of a given design is required, the profiling is outsourced to a small, family owned waterjet shop. This saves an enormous amount of time and labour and ensures reliable repetition of a design. The handle scales are also rough cut via waterjet, which further speeds up the process. Both knives and handle scales still require clean up, though much less than if they were cut by han
Once the profile is finalized, the bevels are marked and roughed out with the belt grinder. This is done without guides or jigs and requires a steady hand and countless hours of practice.
Each bevel is finished by hand with a file. Both knife and file are locked into a jig that ensues a consistent bevel angle. This process is labour intensive and time consuming, but it is necessary to establish clean bevel lines that perfectly match the blade profile and are equal on both sides.
Jimping is cut by hand with a variety of small files.
As a final step before heat treat, each knife is surface sanded and all the edges rounded using a belt sander and rotary tool.
The handle scales are either cut out by hand or by waterjet, depending on quantity. The profiles are cleaned up using a belt grinder and sanding drums.
The holes are drilled and countersunk for the attachment screws using the knife blade as a guide. If the scales are to be flat with a beveled edge, this is done on the belt grinder.
The texturing is created using a rotary tool and sanding drum. Every surface is then sanded by hand using a progression of rough to fine grits.
Once sanded, the scales are polished using a high speed buffing wheel.
Each knife is individually heat treated. This involves bringing the blade up to approximately 1,500 degrees Fahrenheit and holding it there for several minutes. The blade is then quenched in oil to rapidly cool and harden the steel. At this point, the steel is extremely hard and brittle.
The second part of the heat treat process is tempering. This involves heating the blade up to just over 400 degrees Fahrenheit for several hours. The purpose of this is to soften the steel just enough to make it flexible and less brittle, while still maintaining adequate hardness to hold an edge. All of our knives are powder coated to protect the steel. This process requires the coating to be heat
Once both blades and handle scales are finished, they are assembled using chicago screws.
All Courage Project knife sheaths are made from kydex, a heat moldable plastic. This is the same material used for modern holsters. The kydex is heated to 325 degrees Fahrenheit, and then pressed around the knife to take on its shape.
The sheath outline and rivet placement is marked, the holes drilled, and the rivets set. Much of this stage is determined by how the knife is to be carried and what mounting hardware will be used.
The sheaths are then cut out and the retention adjusted so that the knife is held securely, but can still be removed from the sheath with ease.
Every edge is meticulously hand sanded and buffed for a perfect finish. Once the sheath is complete, the mounting hardware is attached.
The final step is to put a razor edge on the knife. This is done using a traditional hand sharpening device that uses a jig and guided sharpening stones to apply a perfectly consistent edge.