GRAND RAPIDS, Ohio — The floor is an irregular amalgamation of stone, dirt, grit and ash. The walls are rough siding, weathered gray and etched with the texture of many seasons on the outside, and adorned with primitive iron tools on the inside.
A massive mechanical hammer is anchored against one wall. It is more than 100 years old. Anvils, a huge vice and a coal-fired forge are spaced about the small barn. The 4,000 pound metal work table required a fork lift to reach its position in the corner. The smokestack exhaling heavy smoke betrays the structure’s purpose – this is the workshop of a man who forges raw metal into fine blades.
PHOTO GALLERY: Beaver Creek Forge
Fire and force and physical science are manipulated and managed here at the hands of Forest “Butch” Sheely, a blacksmith who specializes in crafting knives and tomahawks. Mr. Sheely sketches out each piece on a blackboard, but there are no plans, patterns or diagrams to follow – each hunk of raw metal is heated, hammered, ground, honed, filed and tapered by this retired manufacturing engineer.
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At his Beaver Creek Forge in rural western Wood County, Mr. Sheely heats bars of high-grade steel, often from old metal files, to about 2,000 degrees in his open furnace, and then begins shaping what will eventually become a classic Bowie knife, or a hunting knife. He also makes unique axes and pipehawks, in all cases starting with the crude metal stock and creating tools that are more works of art than weapons.
The custom handles of curly maple, French walnut, desert ironwood, or antler, horn or bone are also his creations. He makes the hand-stitched leather sheaths, does inlay work and engraving, as well.
“As a knife-maker, there are a lot more skill sets you call on than just the forging of the metal,” he said.
Mr. Sheely started bladesmithing and blacksmithing more than 30 years ago, primarily making knives, tomahawks and various other items for re-enactors. Now his work is done mostly for high-end collectors. A recently completed antique style Bowie took four weeks of work to create that single knife.
“There’s nothing fast about blacksmithing or making knives. If you are in a hurry, this isn’t for you,” Mr. Sheely said.
Local blacksmith Ernest Deutschman first saw Mr. Sheely’s work in 1987, and both are members of the Northwest Ohio Blacksmith’s organization.
“As far as I’m concerned, his stuff is perfect,” Mr. Deutschman said. “There’s a lot of creativity involved in his work. He can throw a piece of metal on the forge and turn it into something amazing. He is exceptional – one of the best at what he does.”
First Published November 29, 2015, 5:00 a.m.
