This miniature Braveheart inspired whiskey/martini sword took me about 30 minutes to make.
Tools you need:
1 framing nail
Small brass nail or thick brass or copper wire
drill with a small drill bit (1/16)
Here is the beautiful video of the making process.
Step 1: Making a Handle
First we need to make a hole in the nail for the future handle guard. I fixed the nail on the anvil with the clamping wrench and marked the hole with a center punch. When i drilled the hole with an 1/16 drill bit.
Next step is shaping the handle. It's easy to do with an improvised lathe (drill) and a file. After I finished shaping with a file, I polished it with a 250 and 800grid sand paper. It's easier to polish the handle at this stage, while the blade is not flat yet.
Step 2: Shaping the Blade
Now you can try yourself as a real blacksmith, but on a smaller scale. =)
Heat up the nail with a blowtorch and bang it with a hammer on an anvil. Nail is pretty soft than its red hot. If you don't have a blowtorch you can still flatten the nail. All you need is a bigger hammer and more patience.
After initial shaping of the blade on an anvil, I flatten it out with a file.
Step 3: Sharpening
I used a file to setup sharp corners of the blade. Then polish it with the sandpaper 250grid and 800grid.
Step 4: Making a Handle Guard
To make a handle guard we need a small brass nail. Put it through the hole we drilled before and secure it with a few bangs of hammer. Cut the ends with pliers. Brass is very soft metal, you don't need to make it hot to shape. few hits oh a hammer and the handle guards will be flat. Then you can band them and finish them with files and sandpaper.
The more you sand with a high grid sandpaper the more shiny your sword will be.