I’m excited to share particulars a couple of moist shaving mission I’ve been engaged on over the previous a number of months. The Spearhead Security Razor Case is a contemporary copy of the unique Gillette Khaki Set – a 100-year outdated design that has stood the take a look at of time.

It began with a seek for the proper journey case for my security razor.  Since then it has grown right into a relationship with a navy stitching contractor, a brand new LLC, lots of trial and error, and finally a brand new moist shaving accent.

Impressed by Historical past

I wished to make the Spearhead Case as near the unique 1918 Khaki Set as doable, however I knew there can be minor modifications mandatory.  Because of this the case is “inspired by history” and never an genuine historic copy.

The case holds true to the overall dimensions and contours of the 1918 Khaki Set from my assortment.  The one modifications we made to dimensions have been to deal with shrinkage (the unique has shrunk over the previous century) and to deal with the distinction in thickness/flexibility of the fashionable nylon.

There are another modifications past the up to date nylon cloth.  The colour is Foliage Inexperienced (AKA Military Grey) – a contemporary navy grey with simply sufficient inexperienced to pay homage to the unique Khaki Set.  The straps inside have been upgraded from canvas to elastic to accommodate razors of all sizes.  Lastly, we put two straps to carry the razor head.  This enables the pinnacle to be positioned with the threads up, which helps to accommodate bigger heads like Rockwell.

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Constructed to Final

We centered on sturdiness, which impacted every little thing from the supplies to the the stitching.

The Mil-Spec 500D nylon may be very put on resistant and it resists shrinking, staining and water harm.  Each level of pressure is strengthened with extra stitching utilizing industrial bonded thread to make sure the stitches keep safe over time.  The material is die lower for precision and double-layered for weight and sturdiness.

We scrapped many instances early within the manufacturing course of (like the complete first manufacturing run – however that may be a story for an additional day).  But it surely was price it to create a moist shaving product we’re happy with.

We all know that many moist shavers use heirloom-quality razors.  Our aim is to create a case that lasts so long as the razors it protects.

Made within the USA

I realized that there’s extra to calling one thing “Made in the USA” than simply manufacturing it right here.  Along with the labor, almost all the elements have to be home supplies.  In our case, it meant that the material we use must be American-made.

Home supplies price extra however we felt it was necessary to the legacy of the Khaki Set to fabricate an American-made product.  As such, nearly all the Spearhead Case inputs are manufactured within the USA.  The case was designed, prototyped and sewn in Ohio and Western New York utilizing nylon cloth made in mills all through the US.  The Spearhead Case is a real “Made in the USA” product.

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I journey regularly for work and I wished a security razor case that was small, gentle, and sturdy.  A pal owned a Gillette Khaki Set from WWI – a small canvas case that was precisely what I wished.  I bought my very own classic Khaki Set however the case was too outdated and stiff.  I discovered my spouse’s stitching machine and tried to make my very own.

My try at a home made case was semi-successful.  It was ugly however useful (it was my first time utilizing a stitching machine).  However my actual want was to improve the case to fashionable navy supplies (500D nylon) whereas preserving the design and aesthetics of the unique single-snap Khaki Set.  If I wished an upgraded case I would wish some exterior assist.

I knew that navy contractors would have the tools, supplies and experience to breed the Khaki Set.  However discovering a contractor to make a handful of razor instances was an uphill battle.  I wasn’t making an attempt to order 5,000 items and the moist shaving business isn’t precisely “tactical” in nature.

I obtained lots of rejection from contractors, however that was not a shock to me.  I knew that if I wished to see the mission by way of I would wish to point out a stage of dedication.

So I jumped in head first.  I arrange an LLC, funded a enterprise checking account, and created a brand new firm.  Spearhead Shaving Firm was shaped.


I discovered a contractor who was an incredible match for my mission.  They focus on small pouches and luggage for navy & police, however in addition they do personal contract work.  Most significantly, they understood my imaginative and prescient for a high-quality American-made razor case.

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I underestimated the problem of prototyping.  Some materials wrinkle and bunch when they’re sewn round corners.  Some are too skinny whereas others are too stiff.  There are fixed tradeoffs for sturdiness and aesthetics.  Colours are laborious to guage from a swatch.  Imported supplies are cheaper than US supplies.

What appeared easy – recreating the Khaki Set – concerned extra selections than I anticipated.  I settled right into a imaginative and prescient for the Spearhead Case that made decision-making simpler for me.  I wished the case to be:

  1. Impressed by Historical past
  2. Constructed to Final
  3. Made within the USA

These rules guided lots of the selections through the growth of the Spearhead Case.


I’m happy to say that we are actually in our second full manufacturing run of the Spearhead Case.  I’m honored and energized by the optimistic response to this mission.

Spearhead Circumstances can be found at SpearheadShaving.com and at Maggard Razors.  I additionally provide a number of present units with razors, blades, brushes and shaving soaps.

Thanks for studying this submit, and thanks prematurely for those who resolve to buy a Spearhead Case.  This has been a gratifying mission and I’ve loved making a product to serve the wants of moist shavers.




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