How I Made The Best Tactical Knife Ever Made...Even Better

When Les De Asis wanted a serious folding combat knife that featured the Michael Walker-designed liner lock with a ball detent, he teamed up with Chris Caracci to develop the AFCK. This stands for Advanced Folding Combat Knife. I’ve also heard it called the Armed Forces Combat Knife, which is incorrect but would be a great name too. Whatever you want to call it, it definitely ushered in, or possibly even created, a new genre of tactical folding knives.

Chris and Les only collaborated on one knife. It is my understanding that Les has a nasty habit of not paying designers. Allen Elisewitz and Ernest Emerson have fallen victim to Les, so I wouldn't be surprised if Les did the same to Chris. Although I love the AFCK and praise it for being such a groundbreaking design, I am directing that praise to Chris Caracci. I’m just thankful that Benchmade made them and did such a consistently good job with it.

Chris Caracci, a former Navy SEAL, came up with this incredible design. While it isn't as advanced as some of the newer knives out there, I can tell you that the one I've been carrying for over 20 years is a real workhorse. As shown in the photos below, much of the black coating has worn off the blade.

 

I'm really glad the AFCK was created and enjoyed such a long production run. It went through many upgrades and different versions. For this article, I’ll focus on the Large AFCK 800BT and the Small AFCK 814BT. Both feature 154CM blades, which replaced the ATS-34 steel used for several years. Both steels are exactly the same, except that 154CM is made in the USA by Crucible, while ATS-34 is made in Japan by Hitachi. 

My 800BT arrived one day and sat on the front porch all day until I got home from work. I’d say that was during the winter of 1997. This particular one checked all the boxes when it comes to fit and finish. The blade had a beautiful symmetrical edge and grind, the oval hole was a thing of beauty, and the lock-up of the liner lock was right at 50%, which is where I like them to start. The photo below shows 20+ years of use and more than 50% wear, but it’s still solid!!

Many people seem to prefer early locking mechanisms. Maybe they think that over time, the lock will wear slightly and move closer to the center. It’s a sturdy lock-up with no wiggle or play. The G10 had the typical texture expected on all Benchmade G10 knives at that time. The clip is Parkerized, unlike the painted clips found on other Benchmades today. The bushings are nylon and work well, but I’ll discuss that in Part II. They aren’t as slick as the oil-impregnated bronze bushings you see now, but remember, this knife is very old school and one of the “foundation” knives for all the others you see today. It really had no predecessor. When it hit the market, it was a huge upgrade from anything else available. Sal Glesser of Spyderco developed the thumb hole, and thank goodness he was generous enough to license its use to Benchmade. Otherwise, this knife might never have been made, or it would have had thumb studs like the axis lock version. I personally find thumb studs get in the way. On some knives, such as the Chris Reeve Sebenza, thumb studs work, kind of. But lately, I've been removing many thumb studs on those and drilling holes instead. It makes that knife much better. Maybe I'll write about that in a future article.

Spyderco was making pocket clip knives with holes, but they all were very plain and used mid locks, not liner locks. Michael Walker’s liner was in its early stages, and the knife industry was on the verge of a boom in new designs because of two patented ideas: the liner lock and the thumb hole. What a perfect match made in knife heaven. The AFCK, in my opinion, was the first true entry into the world of “Tactical Folder.”

 

If you have ever held an AFCK, you know how enjoyable it is to look at. If you have ever used an AFCK, you understand how the simple design makes it perfect for long and heavy use, and it can be gripped in many ways for nearly any situation. With some practice, it can be out of your pocket and open in an instant.

 

Now, here’s where you might think I’m crazy, but my idea may have led to a design change that you now take for granted on your pocket clip knives. If you look at the amazing shape of the AFCK handle, it clearly suggests it should be a Tip-Up carry knife. But, Benchmade only made it Tip-Down. This forced your hand to deal with the bulkier, square front end of the knife and the thumb grooves on the spine of the blade. However, in the Tip-Up position, the edge of your hand would glide smoothly past the back of the knife as you reach into your pocket for change or car keys.

I called Benchmade to ask if I could send the knife back to them and have them drill and tap holes so I could make the knife a Tip-Up Carry. I was told “No”. That was the entire response—a one-word answer. So I asked to speak to someone higher than a “customer service rep”. The manager of the repairs department was put on the line. I wish I had remembered to write down some names, but I didn’t (I definitely do that now). The repairs manager said they didn’t have the tools or machinery in the repairs department to do what I was asking. He also said that there has been no discussion by the design team about making the AFCK a Tip-Up Carry in the near future. He even mentioned that because of the handle shape, he didn’t see where they could add a clip. End of conversation.

My only limitation on where I placed the clip was the location of the hardware holding the scales and the position of the thong hole. I positioned it as high as I could so the knife would ride nicely low in my pocket.

 

The picture below shows the view from inside the liner and the very end of the screw poking through the hole.

Now here is a picture of my newest addition to the AFCK family, the AXIS lock with M390 steel. Notice where Benchmade placed the clip. Hmmm. Looks oddly familiar. I wonder where they got the idea. I find it hard to believe that, working with a company so advanced in the CNC world of knife technology, Les wouldn’t have said, “Hey guys, let's take an afternoon and plot some new points on the commands of the drill head, make a new fixture to hold the knife, and drill some holes where they should be."

Below are two photos of the knife I modified, on top, and the factory knife.

And a close-up shot.

Well, I have a good hunch that my letter and photographs sent to Benchmade as a follow-up showing the completed project got them talking among themselves and probably quickly led to a prototype. Then, someone probably put that prototype in their pocket and exclaimed, “Hell yeah,” this is the way to go, and never took it out. That’s all it would take. If you can put a knife with almost a 4" blade in your pocket via a clip and still easily slip your hand in and out, then you’ve really got something. Also, I found out that the vast majority of folks prefer Tip-Up. So, not only have you taken advantage of the natural shape of the handle, which acts like a shoehorn guiding your hand into your pocket, but you’ve also oriented the knife in a more popular, useful, and quickly deployable position. If you use the “zip tie” method, you can have it open itself on the way out of your pocket.

 

Wonder how many of you noticed that feature in the photos above. The notch functions like an aiming device for your thumb, and you quickly realize that your thumb naturally hits the hole every time as it should, causing the knife to open almost automatically. It’s an incredible feeling. All it took was a quarter-round bastard file to carefully shape the notch, being cautious not to cut too far into the liner. Then a bit of emery cloth to smooth it out, and you're done. I never sent pictures of this modification to Benchmade, so maybe that’s why you don’t see that feature on their knives now. (Yes, that’s sarcasm) I mentioned the AXIS version of the AFCK earlier. The first one I bought had a D2 blade, and I was honestly disappointed. Why? Well, it’s thicker, heavier, and probably about 5% larger in all dimensions. The AXIS mechanism is fantastic, but why use stainless steel liners? Even perforated, that adds quite a bit of weight. The liners are thicker, so the knife’s overall thickness increases significantly. It’s also wider and longer, making it just a little too bulky for pocket clip carry. The Axis knife tends to pull on the pocket, whereas the older liner lock version with titanium liners doesn’t. So I sold the D2 version and bought one of the M390 with all-black G10, which is contoured and textured very nicely. The fit and finish are better, and it features beautifully anodized standoffs. I thought it would be lighter since I was told the liners were titanium, but most definitely they are not. The thumb hole isn’t oval but round, just like on the original AFCK, though slightly larger. Opening it is still a simple flick of the thumb. The size of the previously mentioned Axis lock version was a bit too much for me, so I put the original clip back on and sold the knife. I don’t miss it for a second. The first thing I did with the new one was remove the pocket clip and replace it with one from the older generation. Thank God they didn’t change the pattern entirely, unlike Spyderco. After successfully modifying my 800BT, I decided to do the same with my 814BT. The smaller knife, with stainless steel liners instead of the titanium ones in its larger sibling, actually made the machining process a bit easier. I still used epoxy as a lubricant and set agent. In the photos, you see my old handle paired with the new blade. I found a NOS AFCK with a very well-ground blade, so I thought it would be cool to swap the new blade into the old handle. It works perfectly, and the lock-up is rock solid. This is my EDC knife. Sometimes I panic and think I’ve lost it because I don’t feel it clip to my pocket, even after repeatedly reaching in throughout the day. Due to the tip-up carry and the handle’s curvature, I never notice it. Over time, my hand has worn the nylon standoff/spacer between the scales smooth.

Here is my Large and Small hanging out together.

With all the newfangled knives out there, many of which I have owned, I always go back to the AFCK for its straightforward utility, quality materials, easy carry, quick deployment, and durable build. Even my Spyderco Paramilitary sits in the drawer 85% of the time because I naturally reach for the AFCK. 

 

In closing, my dream would be if they resurrected the original design with my two improvements and maybe replaced the 154CM blade with K390, 20CV, or even the reliable old S30V. Maybe I should call Les.

                                A couple of pictures of the finished product in my pocket.