This Instructible will take you through the steps and techniques necessary to make your very own medieval letter opener out of some wood, leather, wire and yes ... a bolt. and this will make a great Christmas gift to a medieval enthusiast or a gift for a great Dad for his desk. (who I'm making it for) and as this was a gift this tool engraver would have been cool to engrave his name http://www.craftsman.com/shc/s/p_10155_12602_00961050000P?vName=Power+Tools+%26+Equipment&cName=Power+Tools&sName=Portable+Power+Tools&prdNo=1&blockNo=1&blockType=L1
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Signing UpStep 1: Materials & Tools
Materials:
* Cloth - any kind will work it will only be covered in leather and wont be seen as wide as the grip of your letter opener and about 10 inches long(scrap is just fine).
* Bolt - any kind really but you must think about the shape you want your letter opener to be (size, width, and thickness must be taken into account) i used a 10 inch long half inch bolt(the best is the kind w/out the threads the whole length. (you can find these at home depot pretty cheap) this is what I used http://www.homedepot.com/Tools-Hardware-Hardware-Fasteners-Fasteners/h_d1/N-5yc1vZ1xg6Zar9h/R-100337973/h_d2/ProductDisplay?langId=-1&storeId=10051&catalogId=10053 .
* Wire - between 18 and 20 gauge is best you'll want it to be shiny(I'm using some jewelry wire I got at Michael's craft store it is copper core silver plate wire.) you'll need about 2-4 ft.
* Leather - I'm not actually using leather cause I found some nice vinyl at a local fabric store (this is for the handle so whatever size yours is is what you'll need I'm gonna use about a 18" x 1" piece) can be found at any fabric store.
* Sand paper- 100, 250, 400, and 600 grit
* Steel wool- Kind: #0000 http://www.homedepot.com/h_d1/N-5yc1vZ1xg6/R-100212006/h_d2/ProductDisplay?langId=-1&storeId=10051&catalogId=10053 . for finishing can be found at hardware store .
* Steel Buffing compound- for polishing can be found at a hardware store.
Tools:
* Torch- I used an Mapp-gas torch cause its what I have but a blow torch or a forge would have been better.
* Heavy Mallet- I used a 3 lb. Mallet.
* Files- coarse, medium and fine.
* Pliers or Vice grips- to hold the bolt while striking.
* Ear protection- unless you want a headache (past experience . . . the worst one I've had).
* Heavy duty gloves- I used welders gloves (to protect from burns).
* Anvil- or hard heavy metal surface on which to work the metal.
* Grinder- to rough out surface.
* Buffing wheel- to polish it.
* Vice - to hold letter opener while filing.
I did all my shopping at Homedepot
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I made on from a large nail, just hammering it flat and then grinding it.
For those cheapo's like me, who don't have anything that can heat up metal hot enough, you don't actually need to, it just takes more work to get it flat.
Picture of my "sword"
a few interjections- that's not an oxy-acetylene torch, looks like a mapp-air setup.
it might be worth adding something about hardening/softening steel. i.e, once heated until orange, the faster steel is cooled (via quenching) the harder and more brittle it become. conversely, if allowed to cool slowly, the more slowly it cools the softer it will become.
Out of curiosity is that a railroad track anvil you're using?
Thanks for the link though, I'll have to browse some more.
here is a bench block
And I was thinking, if all I need is the flat part of an anvil, couldn't I just buy a steel block from a metal supplier?
The only thing I would need to know is how tall it should be, between 1/2" - 4" or something.