Introduction: 10 Dollar Diy Sword

I knocked this project out in a few hours and you could probably do it in a shorter amount of time not making the mistakes I did. It's a fun simple metal working project that has a pretty cool result. It might not be the most professional sword in the world though it is cheap and easy to make so it balances out. I hope you enjoy and be safe while wielding the sword.

Step 1: Stuff You Will Need

Picture of Stuff You Will Need

1. Bar of steel

2. File (If you have a grinder that is 1000 times better.)

3.Grip Material (I used baseball bat grip.)

4.Hacksaw

That's it for the basic build. If you want to make a hand guard like I did just a couple more things.

4.Metal Plate ( Thick flat piece of aluminum)

5.Drill

Step 2: Draw Out a Pattern

Picture of Draw Out a Pattern

Basically, draw out whatever pattern you want on your sword. I personally made mine extremely simple but if you want to draw some crazy pattern go ahead.

Step 3: Cut Out the Pattern

Picture of Cut Out the Pattern

I then used a hacksaw to cut out the pattern I drew on the sword. Again in my build, I used a very simple pattern not just because I'm lazy but some cuts would have been difficult to cut out so keep this in mind if your only means of cutting metal is a hack saw like me.

Step 4: Lots and Lots of Filing

Picture of Lots and Lots of Filing

This is the longest part of the build. You want to start filing at a 45-degree angle and slowly move the file until it is nearly parallel to the sword. This process took me about an hour and a half. Also if you want you could continue and further sharpening with a sharpening stone or belt.

*Also leave a section at the bottom not sharpened, size depending on the size of your hands.

Step 5: Guard and Grip

Picture of Guard and Grip

The Guard is simply an aluminum plate I drilled filed to press fit on the sword then I added super glue to help the fit.

Step 6: Check Out Some of My Other Videos and Projects,

Picture of Check Out Some of My Other Videos and Projects,

Thanks for reading this and if you liked this go subscribe to my youtube channel GarageBot at this link https://www.youtube.com/channel/Garagebot. There I upload every other week on Tuesdays and you can see some more of my projects that I am currently working on. Also, follow this account on Instructables for in depth build guides to my projects. I hope you liked the project and make sure to leave any suggestions below.

Comments

esoler (author)2017-08-14

all that filing would have been a lot easier if you clamped the bar flat on the bench and filed one side at the time. you probably need to mark the middle of the bar so you don't overfile

YMMV

GarageBot (author)esoler2017-08-14

Noted thanks for the advice. :)

Drake88 (author)2017-08-06

That bar steel will not hold an edge for long. Try cutting cardboard boxes with it for about 10 to 15 minutes. Your edge will be dull and mostly useless.

Far simpler to use use an old leaf-spring from a pick-up tuck or car. The leaf spring will be made form spring steel, which has more carbon in it and that makes the steel hols an edge far longer. You will likely need an angle grinder to shape and place an edge on the blade, but you need to be careful to not lets the steel get too hot, or you will lose the tempering - which will cause the edge to fail.

I suggest doing some reading on tempering and annealing of steel and other metals.

GarageBot (author)Drake882017-08-09

Thanks, I don't have an angle grinder yet but I am considering purchasing one, also yeah it really doesn't hold that edge for very long at all.

Drake88 (author)GarageBot2017-08-09

If you use the angle grinder once you get one - be careful to wear eye protection ALL the time, and a heavy(or leather) apron when using a wire-brush wheel - those little wires can come loose. When they do, they can fly a good distance, but they can also STICK into things close by - like you. It isn't a fun experience having one or two of those things pulled out....

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