Form the rough shape of a blade using metal cutters. Then, you can use a file to create the edge and smooth out the surface. Leave a segment at one en...
A while ago at a robot competition, my friends were playing with solder wire, making flimsy little swords and hitting each other with them. Later, I was wondering if it was actually possible to make a usable blade with solder, and so the Solder Sword was born. (Ok, its really just a little knife, but it looks like a miniature sword.)
Scrap pieces of waste solder Whatever you want to use for the handle and sheath
Soldering Iron Candle Hammer Anvil (I used a metal weight) File/Sandpaper Pliers Dust Mask Goggles
Step 2: Casting A Solder Ingot
I started by making an aluminum foil mold in the shape of a long bar, and melting solder scraps in it using the soldering iron and candle.
Step 3: Forming The Blank
I hammered the bar flat using, well, a hammer. Solder is brittle, but you can make it easier to flatten by holding it over the candle with pliers. If it does break, you can solder it back together using the iron. At the end you should have a long flat bar of solder.