Thread: sword making

I don't know about swords, but that's my kinda carpentry!

Some nice innovative solutions. What sort of steel are you using? I'm guessing it's for re-enactments?

It will be good to see the finished article.

Ray

The steel is spring steel. I got it from a scrap yard. It is hellishly hard though. I went through nine 1mm cutting discs just to cut it out.

Grinding the sword in to shape. I use a 4" angle grinder. The steel is 6mm thick so I have a piece of 3mm plate as a guide to how far I grind the edge. I always stop with the grinder a bees d**k higher to allow for filing and sanding. This steel is very hard so the grinding process is ok. If the disc digs in to the steel....throw the project away.

I've gotta say, I really like your grinder jig!

Cheers, it may look a bit iffy but it is solid and cuts or grinds, in straight line, perfectly.

A bit of ingenuity goes a long way.

It looks like your workbench is an old door and your work area is carpeted?
I like it!

Just an update if anybody is interested. The pics show the sword after grinding and sanding. The cross-guard is just mild steel, the centre cut out using a drill and a nice small file. The last one shows the blade ready for the hilt.

Cheers.

Originally Posted by wireliner

Just an update if anybody is interested. The pics show the sword after grinding and sanding. The cross-guard is just mild steel, the centre cut out using a drill and a nice small file. The last one shows the blade ready for the hilt.

Cheers.

Plenty of interest. What's the story behind the making of the sword? Role play etc. Looks like you've done it before.

When I see swords etc I always think of "Highlander" - great movie.

Ben.

Like your grinder jig.

Not always practical to put it in the bandsaw, so could see this working in the shop.

Ben, my interest in swords came from "Highlander". I started from scratch with a piece of FMS. No good. Spring steel, research and time. I have made about 10 swords, all sold or given as gifts.

As much as my wife hates it, my blades always tend to end up very sharp.

Cheers.

love what you did there, thanks for sharing.

that certainly looks good

more photos of each process would be great

The first pic shows the cross guard fitted on to the tang. The tang is what the handle is made on. Some guys make what is called a rats tail tang. Just as it sounds...skinny. They tend to snap, thereby sending 36" of sharp pointy steel flying. Not good!

I decide the length of the handle and cut the tang to suit. The pommel and cross guard are welded in to place...carefully. The pommel is the bit at the end of the handle. It is there to stop your hand from sliding off and keep the handle in place.

The handle is just 1/2 round glued on to the tang then sanded, filed, grinded into a form that feels good. I finish the grip using a thin leather strip from Spotlight. A bit of fabric glue painted on with an art brush on to the wood about 1" at a time and carefully wind it on with a bit of tension.