Measure and mark the handle to 71mm using a caliper. Cut cleanly with a hacksaw or rotary tool. Smooth the cut edge with a file.
3. Trim the Screw
Cut the 60mm M5 socket head screw to 52-53mm. Deburr and clean with alcohol.
Why stainless steel?
We chose a stainless steel M5 socket head screw because it will not rust—a critical consideration for a razor that may live in a humid bathroom or a sealed Altoids tin, where moisture buildup can silently destroy lesser metals. Stainless steel ensures corrosion resistance, long-term reliability, and zero maintenance—a prepping card essential.
4. Epoxy Bonding
Coat the inside of the handle and the screw threads with epoxy. Insert the screw and tighten finger-tight until the hex head sits flush. Let cure undisturbed for 24 hours.
5. Final Assembly
Reattach the razor head. Final handle length: 76mm
Final weight: 29 grams—virtually identical to the original Gillette Military Tech.
Field Deployment
Pack the razor into an Altoids tin with:
• Razor head and handle
• 5 Blades (ASTRA or preferred)
Use a 3D printed insert for secure, rattle-free storage.
Historical Doctrine
The original Military Tech razor was designed by Gillette for:
• Cold water shaving in austere terrain
• Minimal gear: shave stick + hand-lathering
• Mild blade exposure to reduce irritation
• Compact for field or barracks conditions
For decades, Black and Latino barbers recommended mild Double Edge (DE) Safety razors like the Tech and a single With the grain pass (WTG) to reduce the risk of Pseudofolliculitis Barbae (PFB)—a painful condition caused by ingrown hairs, especially in men with curly or coarse hair. Cartridge and Aggressive razors increase the likelihood of hair re-entry and inflammation. Mild DE razors, with reduced blade exposure and smoother glide, offer safer, more comfortable shaves and long-term skin health.
The Sterling’s long, lightweight handle causes users to bear down, increasing pressure and irritation. By restoring proper weight and balance, your modified razor lets the blade and geometry do the work, reducing trauma and honoring the original Military Tech’s legacy.
The Sterling’s Tech-style head geometry preserves that mildness of the very successful Gillette Tech. With a trimmed handle and weighted insert, it becomes a modern prepping card artifact—compact, durable, and morale-sustaining.
Dual-Use Capability
Your modified razor isn’t just a field improvisation—it’s a refined, mild shaving tool that performs with equal grace at home.
• Ideal for daily use, especially for sensitive skin or cold-water shaving
• Preferred geometry for men with curly hair, reducing risk of PFB
• The combination of Stainless Steel and Plastic handle construction makes it temperature-insensitive and easy to use in hot or cold conditions
• Weighted handle prevents pressure-induced irritation
• Compact enough for rucksack deployment, durable enough for bathroom shelf duty
• Stainless steel hardware ensures rust-free performance in humid or sealed environments
• A Shaving implement that bridges discipline and comfort, legacy and utility
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Author Bio’s
Hansel Rayner, PA-C, is the founder and lead clinician at Central Georgia Adrenal and Reproductive Endocrinology. A former Cav medic/scout on the Korean DMZ, he’s nationally recognized in Adrenal and Reproductive Endocrinology and the author of numerous articles in the field of Wound Ballistics and Shaving for soldiers.
Cindy Zhou, mechanical engineering student at the University of Florida.
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