How to Forge a Khopesh





Introduction: How to Forge a Khopesh

Hello everyone! I have just finished one of my coolest projects so far (in my opinion). So my cousin being a blacksmith and me a carpenter, we often like to get together and combine our talents. This means, of course, SWORDS. And, me being of Egyptian decent, I decided to make one of the sexiest, and most well designed swords know to man: The Khopesh.

Over the course of two days, my cousin and I both worked on our weapons (his a Bowie knife), one day on the blades and the other on the handles. This Instructables, will be mostly pictures with a little text, however, I tend to ramble and will likely write a 2 page paper in the process. Anyways, enough talk, let's begin!

Step 1: Materials and Tools


Spring Steel

Wood for handle (I used rosewood as it contrasted the steel nicely)

Wood Plugs (optional but makes the handle stronger)








Power hammer

Long drum of quenching oil or water



Lots of clamps



Step 2: Flatten the Steel

Using the forge, heat up the steel then unravel it and flatten it like a raccoon on the highway.

Step 3: Sketch Out the Outline

This is pretty self explanatory, sketch out the outline. I just free-handed it from a picture on the interweb onto the worktable using a grease pencil. The overall length of this sword is around 43 inches.

Step 4: Bending

Begin to draw out and flatten the steel, then start to give the Khopesh its curves.

Step 5: Sharpening

Clamp the Khopesh to the table with the blade sticking off then, using the angle-grinder, sharpen the edge.

Step 6: Character

Just to brake up the uniformity, I added a grove along either side of the steel between the blade and the handle.

Step 7: Distractions

Of course, no project is complete without a few quality distractions, and in our case, it was one of my cousins goats getting stuck in a net. We had a fun time getting her out of that one.

Step 8: Make It Holy

I apologize, but I got a thing for puns. Anyways, drill holes in the handle so that you can connect the handles to the blade.

Step 9: Tempering

To temper it I followed the advice of a couple instructables. Of course, tempering is not necessary however, if you plan on using this in battle or as a practice weapon, I highly recommend it. However, be warned, as this is a long sword it can be difficult to temper, and can be curved or cracked in the process, so proceed with caution.

Step 10: Attaching the Handles

Trace the blade handle onto the wood. Then cut it out and get it as close to the blade handle as possible. The next step is to sand down the handle to the thickness and curvature you want, which must be done before the attaching, so any finishing you want done, make sure you do it now.

Then, once you have the wood handles where you want them, Clam one of the wood handles to the blade handle and drill holes into it from the steel side so the holes line up perfectly. Then epoxy that side to the blade. Once the other side is dry, take off the clamps, match the other wood handle to the blade handle, then clamp it and drill the holes threw the already drilled wood and metal handles and into the new wood handle so that the holes all line up perfectly. Then epoxy the other side to the blade as well, clamp it and wait till it is dry.

Once the handle (collective of all three) is dry put a little glue on the wood joiners (little wooden dowels) and hammer them through the handle. This gives it extra strength connecting all three pieces. Next, cut the excess of the joiners off and sand them down to be flush with the handle.

Step 11: Finishing

To finish it put several coats of polyurethane on the handle. Let it dry and you're finished (last one I promise).

Step 12: Le Fin

Well, that's all folks, hope you enjoyed it, let me know if you have any comments or question.

Thank you and God Bless!



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    I guess step 8 is Saint-like, because it's holy....

    Super cool. Man ,I love your work.

    Thank you, I really appreciate it.

    So, i read in the Wikipedia entry that these weapons changed from bronze to iron in the New Kingdom period (between the 16th century BC and the 11th century BC). And now, in the 21st century AD, after only about 3000 years or has changed to steel! Congratulations on a monumental step in weaponry evolution! But wouldn't it be cool to forge one of bronze?

    I would love to forge one from bronze once my skill increases. If you ever do it I'd love to see pictures.

    There is several You Tube Video Documentaries on Bronze Forging you may want to have a look at those and if you are unsure if you can make it try it in mini scale (30 cm should be ample) if done right you will have a matching Dagger if not well just recycle and start over LOL, ;)

    The Originals also did not have any hand grips but made use of checkering so by Egyptian Heritage do you mean one of your parents hails from Egypt or your Blood? (there is a difference) ;) just curios.

    Also, there is a secret about where those Black Khopesh`s came from (the kind given to High Nobility and Royalty in those days) though I doubt a modern or even to Ancient Standards version would ever be made in the near future! it is still worth pursuing, it would be a challenge but the real problem I have in replicating one of those so far is money LOTS of money and I will need certain Documentation and Licenses as well MORE Money! but I do plan to pursue it and once I do end up makeing some I will post some pictures and perhaps (if possible/legal) send you one ;)

    That would be awesome if you could! And, by Egyptian Heritage, I meant that my Dad is Egyptian, and I grew up there.

    I, see well than if you REALLY want to be all technical and Academic than actually your blood line goes towards the Arabic Tribes more specificly the Pershian Blood Lines ;)

    Why? Because the modern day Egyptians is really the Persian / Arabic Tribes who through some ancient contract was given Custodial Rights to Egypt to protect the land and its monuments until a specific time (more on this I can not reveal here) sufficed to say Egypt's current government and DR. Hawass both know of this contract and also who the real ancient Egyptians / Ergo Real Egyptians were and still are ;) in the end it all comes back to ones Blood Line and Heritage from a Genetic Stand Point ;)

    At least if you want to be all technically correct and such! LOL :P I did not mention this to offend you though just to educate you a bit on the truth of the matter (blood lines is rather important even today and so it is only fair you get a real starting point should you wish to pursue your blood line through history ;) )

    As for the Kopesh well it is not so much the money or making that concerns me but the Laws and Regulations on Exporting (of course it would not be sharpened) still we will see when I get there ;)

    Yeah, my Aunt always got offended when people called us Arab because our family is from pharaohnic times bloodlines, and Arab is from when the Muslim groups came into Egypt and aren't actually pure blooded Egyptian like my Dad's side of the family.

    Much like my own ;) speaking of which I think in that case the photos I uploaded to my profile and so also the part about my self I just wrote specifically for you (you will need to access your mind through your Genetic DNA/RNA Make up To access your Ancestral Knowledge to decode what I have REALLY Written) should prove that point and so also your claim of Royal Heritage to me (this is needed as certain things is best kept in the Sovereign Community) also, what made you choose that particular style of Kopesh? or was it Autosyncratic (meaning you went with your gut / Feeling)?

    Should you need help with Accessing "the Red Path" as Cain called it send me a Private Message and I will assist you, I do not expect you to know how to do this due to certain aspects influencing life here at this moment in time.