1. Weighing of Metal
First of all the metal required for making a khukuri is measured. The metal used to make the khukuri is Carbon steel from railway track which is high in quality and strong as well. The weight must be measured properly. To make a quality khukuri of required size the proper weight of metal is essential because if the proper weight of metal is not taken then it may vary the weight of the same sized khukuri. Therefore the proper weight of the metal is important.
2. Hammering and Folding the Metal
After measuring the proper weight of the metal, the metal is heated to a very high degree temperature and when it becomes so red then it is hammered continuously. This process is very hard and continuous. This gives a metal to shape and size accordingly. After this process we can change the shape of metal into our desired khukuri shape.
3. Giving Metal a Khukuri Shape
When metal is heated and hammered enough to bring into its real shape then craftsmen change the metal into its proper shape. It is skillful work and can be done by skilled craftsmen. This process is little bit tedious because repeated work is needed to bring the khukuri blade into its proper shape.
4. Making Blade an Extra Strong
When the metal is given a final shape of the khukuri then the khukuri blade is again heated to maximum temperature and then when the khukuri is very hot red in color then water is poured to make the blade extra strong.
5. Making of Handle
Handle of khukuri can be of rosewood, buffalo horn, brass or aluminum or any other metal. Handle making requires different skilled craftsmen in their related fields. Rosewood handles are made by different craftsmen, metal handles by other craftsmen and buffalo horn handles by other craftsmen. First the rosewood is cut into its required size and then it is shaped into the required size and designs according to the size of the khukuri. The design of all handles of every khukuri is almost same. The metal handle making process includes the selection of proper metal then the metal is heated and brought to its handle shape. And the buffalo horn handle making process is much similar to that of rosewood handle making process. First buffalo horn is cut into a required size then it is shaped into the required size and design of the handle according the size of the khukuri. All the handles are slightly designed for the beauty and the comforts of carrying the khukuri. Then the handles are made holes vertically in the centre so that the one end of khukuri can be inserted into the handle for the grip. And this is how the firm and comfortable handles are made.
6. Joining the Khukuri with its Handle
After both the khukuri and handle is made then comes the turn of combining them together. Combining khukuri with handle is done with the help of Laha a Nepali gum which is much like a candle and mostly used for seal the government documents in Nepal . First the Laha is melt and poured into the whole of the handle and the gripping part with the khukuri is inserted into the handle. This gives a solid grip to the handle with the khukuri.
7. Filing of the Khukuri
After joining the khukuri blade with its handle the blade then there comes a process of filing of the khukuri blade. This is very important work because it gives a khukuri real smooth and sharp. It needs an experienced expert to file a khukuri blade because the sharp point of the khukuri blade is very sharp and if not done properly the sharp point of khukuri may get damaged. Which means the whole process will be meaningless.
8. Sharpening of Khukuri in a Traditional Way
After filing the khukuri blade is sharpened with a traditional way. It includes entirely hand process and hand made tools. Experts do the work very carefully and takes little bit more concentration. So it is done quite carefully and makes a quite difference.
9. Shining the Handle
In this stage the handle is polished for its final look. The rough part of the handle is removed and polished to make it even smooth and beautiful.
10. Shining the Khukuri Blade
In this stage the khukuri blade is polished to give khukuri blade an extra shine. Some khukuris are extra shined and some khukuris are normally shined. It depends upon the nature of the khukuris. The khukuris shined very smoothly are used specially for decorations and the khukuris shined normally are used for cutting purpose. But one thing should be kept in mind that the quality and the cutting power of both extra shined and normally shined khukuris are the same.
11. Making of two small knives
Khukuri comes with two small knives with it, Karda and Chakmak. Karda is quite sharp and specially used for cutting small things like thread etc. and Chakmak is not sharp is used to sharp the khukuri blades. Both these small khukuri knives making process is same like the main khukuri blade.
12. Making of Scabbard
Most commonly scabbards are made of rosewood. But scabbards are also found in Buffalo horn and metal. The rosewood scabbard making process includes two main processes. First the inner frame which is made of rosewood and the second one is wrapping the rosewood scabbard with water buffalo hide. First the two layers of rosewood frame is cut into a proper shape and size according to the size of the khukuri blade. Then both the layers are combined giving enough space for the khukuri blade to enter. Then it is very firmly wrapped with a water buffalo hide from outside. Scabbard has a place to hold the khukur blade and it also has two small holes for karda(small knife) and chakmak(shiner) which are the set of khukuri and used to different purpose. Buffalo horn and metal scabbards are also made like the same way. After completed scabbard it is polished and decorated with cufflinks, coins, etc.
13. Making of the belt holders (Fharus)
Belt holder to the scabbard is made to make it easy to carry khukuri. This part enables you to hold your khukuri attaching with your belt. Belt holders are small piece of leather which is attached with the scabbard for carrying the khukuri. It is much easier to carry the khukuri when it is attached with your belt.
14. Giving the Final Touch
After all the work has been completed then it comes to the final touch by the experts to the khukuri made. In this stage all the completed khukuris are evaluated for their final delivery to the stores. Here khukuris are checked carefully whether any stains or defect has occurred during the making process. And when everything is done the excellent khukuri or the Gurkha Knife is packed for the deliver is ready to deliver to the customers.
In this way excellent khukuri is made. Though the khukuri making involves various tough processes but the result is worth bearing trouble. When you feel the sharpness, smoothness, beauty and the cutting power of the khukuri then everybody will be amazed.