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This is how I made my Bo Shuriken, it took me a while to figure it out and hopefully my instructable will help you as well.

Step 1: Materials

You wil need:
1) A drill
2) A bench sander
3) Some 150 grit sandpaper (or higher for a more polished look)
4) A steel rod of your choice (I used 3/8 inch but you can use 1/4inch or any other you prefer) found at the hardware store
5) A ruler (or any other accurate measuring device)
6) Parachute cord (optional).

Step 2: Measuring and Cutting

How long do I make my Bo Shuriken?
This is entirely up to you, however, some sizes like 50 ft may be impractical... By general rule of thumb: 8 inches if you have small hands, 10 inches if you have average hands, and 12 inches if you have really big hands.
To cut, simply measure, mark, and cut with a dremel tool. If you don't have a dremel tool then a cut off wheel, or a fine toothed saw will do the trick.

Step 3: Cleaning It Up

If your rod is not already polished, then you can do it quick with a drill. Put the rod in the drill as you would a drill bit and run it while sliding sandpaper across the rod. Be sure to flip it around to polish the end that's in the drill.

Step 4: Get to the Point!

Ok, so some have used bench grinders to sharpen their Bo Shuriken. But I found it much easier to use a bench sander and a drill. Start by marking how long of a point you want( I chose 3/4 inches), then place the rod in the drill as before. Turn on the sander, and drill, then place the end of the rod on the belt to start making the point. Be sure to not keep the rod on the sander too long because it will get very hot. You can either sharpen the point straight or rounded( I chose rounded). If your belt sander had very rough grit, then be sure to go (carefully) over the point with the 150 grit sand paper.
Side note: Please be sure not to touch the rod until you have run water over it or let it cool down a while because it is very hot.
Another side note: this does not need to be heat treated to harden the point, after all I've put my Bo shuriken through, I've not had any problems with the point. If you make yours out of a different material then what I made mine from, you may experience a weaker point and have to heat treat the tip.

Step 5: Finished?

If you have read carefully, and not burnt your self, the congrats you should now have a Bo Shuriken.
But wait... A question mark? Is there more?
Yes, if you want to go a bit further, you can add a nice parachute cord handle. Gut the cord and tie a long two bight turks head knot near the dull end for better grip. Be sure to shrink the cord after you have tied the knot to prevent if from sliding off.
Note: my Bo shuriken turned out to be closer to 9 and 7/8 inches, or to be more precise, 24.95 cm. ( pun not intended)

Step 6: Wait! How Do I Throw?

Explaining how to throw with words is complicated, so I suggest you look up videos of people throwing it and watch how they stand, how they hold the Bo shuriken, how they move their wrist, their release time per distance, ect.
To hold it look at the picture above, and when throwing you release with the thumb.

Step 7: Safety

I must start by saying I'm not responsible for what YOU do with your Bo Shuriken. Use at your own risk and PLEASE DO NOT THROW AT PEOPLE OR PETS*. Alwase watch your surroundings for people and pets so you don't accidentally hurt someone.
Store your Bo Shuriken in a safe place where no children can get ahold of them and/ or play with them.
In the case that your Bo Shuriken may ricochet or bounce back I recemend you not try to catch it.
* unless your being attacked by a life threatening person or pet.
I hope you all have enjoyed my instructable, let me know your thoughts and opinions in comments.
Happy throwing!
<p>if you were to use drill rod, or other good quality steel, you could temper the point by heating it with a torch to cherry red and quenching in water or oil(depending on the steel) and then temper in an over to a light straw color to keep it from being too brittle. that way the point won't get ruined after a couple bad throws, or from hitting a hard target.</p>
I have read much about making knifes and would do this, however, when I made mine the rod is very hard and after lots of throwing and dropping on hard wood I have reason to believe that the factory may have already hardened it. This rod could probably take a hit from a sledge hammer and suffer little damage. If it was not this hard I would have the no shuriken heat treated by a knife maker I know. Thank you for your comment.
<p>So, if you get your steel rod from a big box store, you probably won't know what type of steel alloy that you are getting. It's probably going to be a mild steel (low carbon) that you can use for pins, threaded bolts.</p><p>Probably cold rolled which does harden the steel somewhat, but it's never going to resist bending like a good tool or spring steel. If you are grinding the tip of your spike and let it get too hot (can happen quickly on those grinders), you are going to ruin any hardening from the manufacturer.</p><p>At the very least, keep a cup of water handy and cool down the spike between grinds. If it changes color, you have let it get too hot.</p><p>In general, you can heat up the tip and quench it, but every type of steel has a recommended process for how hot and what to use to quench (oil, water, the blood of your...). Order it online and you can specify what alloy of steel you want and check from the supplier or manufacturer what the recommendations are.</p><p>Here's a materials sheet for O1 tool steel: <a href="https://www.speedymetals.com/information/material9.html">https://www.speedymetals.com/information/material9...</a> as an example</p>
All of this is true, however-- I was trying to make this as low key, affordable, and easy as possible. I would have kept a cup of water with me, but I had no problems going slow and taking my time to prevent over heating.<br> After throwing this at wood, rock, dirt, dropping it on concrete, and other random abuse. I can say there is not really a need for heat treatment processes to be done. For unknown reasons, this mystery steel has survived my testing.<br> If you are an over achiever, and would like to go as far as heat treating your steel, feel free to get what ever kind of steel you would like to use for this project. <br> My instructable's purpose is simply to lay the groundwork for anyone interested in making the bo-shuriken.<br> Thank you for your response, and happy throwing!
<p>how do you gut the cord?</p>
<p>Great idea!!! I love to make my own type of weapons but never thought to this. You just opened a brand new door to creation! Any tips you could give me on this project though?</p>
Yes, first the steel rusts, so when you store it keep it dry and lightly oiled.<br>Second, if you make the knot for the handle don't iron the cord, just gut it and run it a cross somthing smooth, then tie the knot in place and submerge the knot in hot water after to shrink it right onto the Bo shuriken and that keeps it from sliding off. Take your time, have fun, and be safe.
<p>Great idea! Relatively simple but what I wanna know is, how did you get that great wrap on it with parachute cord? I'd have to &quot;punt,&quot; I'm afraid and just use &quot;Duct Tape.&quot; &lt;grin&gt; Or wrap it in leather, but the way you &quot;wove&quot; is, I'm curious how that's done.</p>
I gutted my parachute cord and tied a long two bight turks head knot, you can find a good tutorial for it on the paracordguild website.
Thanks, ZekeF. I have a bunch of paracord and I know how to &quot;gut&quot; it. I'm just worried about how to actually wrap it like that. I'll look at it on the web. Thanks again! <br>
<p>Nice. Very clean.</p>
<p>nice one :) I was wondering about making a bo shruken or a throwing knife for using at my local knife throwing club. :) With this, I'll be the only one with a personalised DIY knife :D</p>
Awesome, glad you enjoyed it!
<p>This an aluminum rod, correct?</p>
Nope, this is steel.

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Bio: Showing the world what can be made with God's creation.
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