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
Step 4: Cut the pommel
Step 5: Solder, polish, clay
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.