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Excalibur Letter Opener

Excalibur Letter Opener
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Drknotter made an awsome Lord of the Rings Sword. Following his lead I decided to make a sword myself. I got on the internet and searched "excalibur dimensions". I divided what I found by 9 and got to making this tiny sword. It comes in useful when I want to get midieval on my letter opening. To make it I used a piece of 3/16" steel rod, a 1/4" shelf pin, a bullet shell, and a little polymer clay. 

Credit goes to my seven year old son for setting up the sword to "look cool" for the photo shoot.
 
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Step 1Hammer out the blade

hammer out the blade

Heat the dowel until it glows and hammer it about 1.5mm thick. For these dimensions you’ll want to hammer out at least 10 centimeters. As you hammer, check the blade against the edge of a ruler to make sure your sword is strait.  To do this you have to hit the rod squarely. If you hammer off center the rod will hook to the right or left.



 

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47 comments
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Apr 10, 2012. 7:51 PMThatKnottyguy says:
Please reply!

Would you mind if i made a stand for this, mentioning your instructable and giving you full credit? Can you give me the dimensions for the width?
Apr 12, 2012. 2:12 PMThatKnottyguy says:
Do you have these for sale at your site?
Apr 18, 2012. 5:10 PMThatKnottyguy says:
Would you want to sell one of these privately?
Jan 6, 2012. 10:29 PMTheAmateurArtisan says:
I remember having one and then throwing it at crab apple trees when I was younger. Was really good at it but then... meh.
Jan 8, 2012. 3:17 PMelectridanger says:
But then...

you took an arrow to the knee
Nov 21, 2011. 11:53 AMcurvy77 says:
i commend you on being one of the few to go into detail about angles measurments and dimensions. you truly make a fine artisian in the metalworking arts. Amazing!
Sep 28, 2011. 7:02 AMMr.Sanchez says:
What about a Stone Stand for excalibur...? that would be awesome.
Nov 5, 2011. 4:04 PMmcshawnboy says:
Hide in the stone an electro-magnet activated via remote to remove or prevent removal of Excalibur by the unworthy?
Nov 5, 2011. 6:35 PMMr.Sanchez says:
So clever pls try....=)
Nov 5, 2011. 8:08 PMmcshawnboy says:
I'd have to build Brent's sword first. I'm limited in what I can do here as my brother-in-law's fussy! I wanted to build a small version of Kiko Denser's "Earth Oven" & he wouldn't allow it.
Nov 6, 2011. 8:14 AMMr.Sanchez says:
Wouldnt allow it..?..well...Its his creation but once the instructables is submited anyone could reply and why not better up the Project.Good luck...!!
Oct 2, 2011. 7:16 AMmslaynie says:
Oooh, congrats on getting featured in the email digest!! :D
Oct 4, 2011. 10:13 PMmslaynie says:
Check your settings. I know I didn't get them for a long time, but now I do. I'm not sure if I changed something or not. They might also be going to your spam folder.
Oct 3, 2011. 7:58 PMisetmyselfonfirefollowinginstructables says:
Hi there, i was juts wondering what kind of torch you used for the project, propane, mapp gas etc.? Thanks
Oct 4, 2011. 1:41 PMisetmyselfonfirefollowinginstructables says:
Thanks so much. I've been looking at your 'ibles, and the way you can transform common items into masterpieces such as this one is incredible. You sir, are a very talented and brilliant person. Hope to keep seeing more from you and keep up the great work!
Oct 2, 2011. 6:39 PMmjursic says:
Lovely little instructable. When hammering it out, here`s a piece of advice that runs counter to your experience: Hammer on an angle. Flip. Hammer on an angle. Flip. Etc, etc. Keep repeating and you`ll get a tapered profile and a ridge up the middle that looks swell. probably not as swell as yours, but it`s worth a try. That`s how I make my blades, and it`s easier to grind them if the profile is already tapered. Please don`t take this as criticism. It`s a beautiful little project.
Oct 2, 2011. 6:41 AMdomestic_engineer says:
very cool.

you should make a polymer clay "stone" to hold it in. then every time you open a letter, you can remove the sword from the stone. Should make paying the bills a little more adventuresome.
Oct 1, 2011. 1:24 AMbrssnkl says:
Do you think about making more of that and selling them, i would love to buy one
Sep 30, 2011. 8:37 AMSNACKS says:
This looks like fun I use to make little Swords out of nails good job...
Oct 2, 2011. 3:40 PMgamos says:
That is a great idea, i will try it.
Oct 2, 2011. 11:31 AMdeathnotx101 says:
If you make a slot into a little rock you can become the king of kings every time you use it. :)
Oct 2, 2011. 10:51 AMwhiteoakart says:
Very nice, Mrballeng. The finished piece looks great and your directions are easy to follow and look quite do-able.
Oct 1, 2011. 11:47 AMmr.squeakers says:
I actually have purchased one of these.
Sep 28, 2011. 10:22 AMbconway1 says:
What size shell casing is that?
Sep 29, 2011. 8:26 AMmcshawnboy says:
Until I saw the picture on the plate I thought you were cutting up .50 cal brass ! Another nice job Brent ! Are you open to trades? Lots of friends like copper necklaces & crosses I've made as gifts for friends that've asked if I could make one from seeing somebody else's. I do wire-wrap & lost wax casting too. I'd love a Spaceship Photo-holder from the master!
Sep 28, 2011. 5:07 PMjsomerhalder says:
you always make awesome stuff, and yes...props to your son for awesome photography styling. Think he has a future career there...
Sep 28, 2011. 7:01 AMmslaynie says:
One of these days we're going to have to work out a trade... maybe exchange a hand-crocheted, custom scarf or maybe a sculpture for a pendant. You make the COOLEST stuffs!! This is gorgeous, and you make it look so EASY!
Sep 28, 2011. 1:10 PMmslaynie says:
Sweet!! Also, I'm working on my first photo instructable, a show and tell of a bead set I made several years ago. Polymer clay for the win! ;)

Thanks for the inspiration!
Apr 16, 2012. 3:08 AMaskjerry says:
It still amazes me... I have a shop full of tools and have not made anything that kool... hats off and two thumbs up.

Jerry
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I've opened up shop =). Click "Vist my shop" to check it out. Or write me at info@mrballeng.com