Excalibur Letter Opener





Introduction: Excalibur Letter Opener

About: Awesome Gear I've designed myself.

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.

Step 1: 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.


Step 2: Shape the Blade

Use a sanding attachment to rough shape the sword. Don’t “sharpen” the entire blade. Leave a section square. Use hobby files to further refine the blade.

To get a consistent bevel on the edge use a marker to color the entire blade. As you file away it’s easier to shape in a strait line. 

Use a grinding disc to remove material for the handle. Don't forget to wear your safety googles.


Step 3: Form the Guard

Heat a shelf pin until it glows. Hammer both sides flat. Use a grinding wheel to rough shape and files to refine. Once you have the shape you want curl the ends downward with round nose pliers and some torch heat. Drill a hole in the middle large enough to fit the handle.

Step 4: Cut the Pommel

Just like the shelf pin, use what you have on hand. In this case I have a rifle shell casing. I mounted it in my drill press, spun it round and used a file to cut a piece off. I then drilled a hole and placed it on the handle.

Step 5: Solder, Polish, Clay

Solder both the guard and pommel in place.

Use progressively finer sand paper to polish the sword. I start with 400 grit, then move on to 1000, 2000, and finally polishing compound on a polishing wheel.

Form polymer clay around the handle and through the pommel. Smooth it out before you bake it in the oven. 

Thanks for reading.



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    Really cool little project!

    Where did you get the dowel?

    Could I make this from a nail if I hammered it out the same way?

    1 reply

    Yes. Have you seen this instructable? https://www.instructables.com/id/DIY-Mini-Swords-And-Knifes/

    Hi there, sorry I'm late to the party, but I'm making something similar and I'm having a very hard time getting solder to stick to the steel. Any tips/ideas?

    1 reply

    The metal must have oxidized. Use sand paper on the surface you are trying to solder before you try the process again.

    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?

    5 replies

    PS. You don't have to feel obligated to mention me. I post my instructables under public domain.

    Do you have these for sale at your site?

    Not right now. For as much time as it takes to make it makes for a better gift then something to sell.

    Would you want to sell one of these privately?

    That would be awesome though I don't have the sword anymore. I gave it to my sister. But If I was guessing I think the blade was 5mm x 1.5mm.

    I remember having one and then throwing it at crab apple trees when I was younger. Was really good at it but then... meh.

    1 reply

    But then...

    you took an arrow to the knee

    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!

    What about a Stone Stand for excalibur...? that would be awesome.