This is my tutorial on how to make bo-shuriken out of a stick of threaded metal. (works also without thread). These shuriken are of better quality and when performed well, they fly and hit very nice.
Materials youre gonna need:
-plyers (to grab the hot metal and temper it)
-your metal stick
-a Dremel or a bench grinder (grinder works better, i dont have one)
-a hacksaw (to cut your stick into size)
-wool (any color you like)
-a file / rasp
-a sharpy (to mark the center of your stick for balance)
-a grindingstone to sharpen your tip (final)
Step 2: Cutting the Shuriken From the Stick
you wanna wrap your hand around your metal stick and mark 1inch after your hand ends. now take your hacksaw or whatever and cut the stick at the mark you made before. Pay attention, the metal may get very hot while cutting. atfer cutting, take your rasp/file and file the one end you cutted before, so it gets smooth and plain. the other end will be our tip.
Step 3: Shaping the Tip
after youve cutted your shuriken to the size of your hand, start shaping the tip. try to get a flat tip, then you shuriken will have more penetration. you can do this step either with a rasp, your Dremel or (works best) with a bench grinder. dont get the exact tip, just shape it. the detail work will be done after that. you may place the cutted & filed shuriken on your fingertip, and just get the balancepoint. its usefull to mark that point, look at foto.
NOTE if the tip is TOO thin, it will break off. so try to make it a good shape, just as on the foto.
Step 4: Tempering the Tip
you may (its good to) temper the tip of you shuriken to make it hard. to do this, just get yourself a charcoal fire, or use one of those high temperature lighter. the tip need to glow very bright and yellow, otherwise it wont work. when its glowing, get yourself a cup of water or oil (i prefer oil) and put the hot stick in there to cool it down. this step makes your metal hard and durable. it good to do this only with the tip. after you tempered your shuriken, it should be somekind of grey, blue and black.
Step 5: Sharpen the Tip and Finishing the Metal Part
After you tempered the shuriken, just take your dremel and go over the tip with it. give the tip a shape, like on the picture. after that, take your grinding stone and SHARPEN your tip, very CAREFULLY, otherwise youll damage the shape. after this, i recommend tempering it again, but it isnt necessary. right here you finished your metal shuriken.
Step 6: Adding the Visual Part
you MAY add this kind of woolen thing at the end of the shuriken, i do it, cuz it looks great. to do that, just cut about 25 pieces of you wool (they have to have the same length), about 5 inches long, and lay em around the end of the metal stick. now take your string and wrap it all around the end of the stick and around the wool, so it wont fall off. when youre finshed wrapping it, make a knot and seal it with your glue. YOU JUST FINISHED YOUR OWN BO SHURIKEN!
NOTE: !!!NEVER!!! throw at animal or people. this is a weapon that can cause serious injuries.
Now get yourself a place to practice with your new shuriken!