Forging for Life

From prominent surgeon to artisan bladesmith

“All of my blades are forged, filed, sanded and finished by hand with minimal use of power equipment. I strive to make an excellent quality working knife that feels good in the hand, is pleasing to the eye and made to last a lifetime or more.”

— Dan Moye of Cattle Dog Forge

Story by Leigh Lofgren

Daniel Moye carefully creates each knife's handle to match the knife's character. Photo by Leigh Lofgren

We all know the expression ‘life happens’ and it’s incredible how things can change in an instant. One minute you’re doing something you always do, and the next minute, you are fighting for your life.

Such was the case for Daniel Moye, whose life as an orthopedic trauma surgeon and bike racer was changed drastically by a horrific car crash. These days, instead of working with a scalpel in his hand, Daniel is handcrafting custom knives and other kitchen tools.

After completing his orthopedic trauma fellowship at Harborview Medical Center at the University of Washington in Seattle, Daniel moved to Athens in 1986 to work at his first practice, Athens Orthopedic Clinic.

One fateful day, Daniel was driving home from a successful bike race in Atlanta on July 24, 2008, when a tractor-trailer truck crashed into his car. The big truck had slammed into the driver’s side of Daniel’s small Prius, leaving him trapped inside.

Emergency crews used Jaws of Life to rescue Daniel from the mangled car, and he was flown by medical helicopter to a trauma center. Daniel said he “coded” several times after his arrival at the hospital. What followed was 18 months in various hospitals for treatments and surgeries, some by his own friend, Dr. John Keating.

Daniel Moye outside his Cattle Dog Forge shop. By Leigh Lofgren

When his right leg became infected, an amputation was scheduled. As a trauma orthopedic surgeon himself, Daniel said he came up with an idea and talked with Dr. Doug Lundy. They decided on an alternative, complicated surgical procedure. The surgery was successful, and Daniel is now able to walk without a cane or walker. He credits his success to hours and hours of physical therapy with his friend, the late Kurt Gelfand, and Sophia Waters of Oconee Physical Therapy and Sports Medicine in Watkinsville.

“When I first got out of the hospital after that year and a half, I had not taken one step, not one,” Daniel recalled. “Initially I was told I probably wouldn’t walk. And then I was able to walk, and I do have some nerve damage. But I owe a lot of it to him (Kurt) giving me the time.”

Daniel Moye carefully creates each knife's handle to match the knife's character.

During this time, Daniel realized he would have to give up his 22-year medical career.

“I loved being an orthopedic surgeon, I really loved it,” he said. “So, I never thought I would find anything that I liked as much.”

However, as one door closes, another opens. Daniel said he had grown up with a father who did a lot of woodwork, “but I just had always thought I’d make knives,” he said. “I’m not sure exactly why. It just seemed like something I would want to do.”

Daniel Moye working in his forge. Photo by Leigh Lofgren

So, Daniel went to make his first knife. He met John Costa, whose forge was a block away from Daniel’s home. John became his teacher and good friend and Daniel succeeded in becoming an expert bladesmith.

Thus began his company, Cattle Dog Forge. At the time Daniel started making knives, he owned two rescue Australian Cattle Dogs (also known as Blue Heelers) named Kylie and Sadie, along with an “honorary” cattle dog, Annie. These three were the inspiration behind the name “Cattle Dog Forge.” Daniel built a workshop and forge on the property behind his home.

“Blade smithing is something I look forward to practicing every day,” he said. “I love the entire process, from forging the blade on the anvil to the hand finishing work on the blade and handle. As it turned out, knifemaking became the perfect therapy for me. It keeps my mind still and my hands busy.”

Each piece Moye crafts is a unique and usable work of art.

Made from high carbon steel with wooden handles, each knife is one of a kind. Daniel said he will sometimes look through his collection of wood pieces for days until he finds the perfect one for the blade. Every step of creating the knife is done in his shop. Forging (heating the steel and shaping it with an anvil), and cooling it in air is done by hand, followed by grinding it and stamping it with Daniels’ maker’s mark.

Each blade is differentially quenched before tempered and finally hand-filed and sanded. Then the handle is affixed and finished with many applications of Tung Oil before its buffed and waxed. The knife is then sharpened by hand.

Each field knife comes with a leather sheath custom made for it by Bud Siniard, of Upland Custom Leather in Watkinsville. From start to finish, the entire process takes about one week.

“My wish is that you will say ‘this is the best knife I’ve ever owned,’” Daniel said.

Moye’s unique knives can be seen and purchased online at cattledogforge.com. Fixed blade field knives, oyster knives, kitchen knives and letter openers are offered, as well as spreaders, ice cream scoops and coffee scoops. And although each is one of a kind, Daniel also offers custom knives based on a client’s specific wishes.

Daniel is a member of Georgia Custom Knifemakers Guild and an apprentice of the American Bladesmith Society. He and his wife, Jean, live in Watkinsville with their two dogs, Maisie, a Tibetan Terrier, and Walter, a Havanese.

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This story appeared in Lakelife magazine, Volume 20, Issue 4 and is the property of Smith Communications, Inc. No portions of the story or the photos may be copied or used without written consent from the publisher.