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Excalibur Letter Opener

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Step 2: Shape the blade

Picture of shape the blade
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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.


 

 
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