Mini Swords for non-forge owners

For a while I've been wanting to make a decorative letter-opener or small knife, and it seems every instruction on the web on knife, or any other metal-working needs a forge. So I decided to experiment and find a method that allows me to make small swords, knives, or letter openers without the afore mentioned forge. And thus we have, the mini-swords.

While these serve no practical value, with very few letters to open these days, they are fun to make, and could make gifts for a fantasy-fond friend.

The images show me making a cutlass, but you can make any sort really, like the one below:

Step 1 Materials and requirements

Even though this does not require a forge, it still needs some other tools:

Materials:
A Nail. 10cm is a good size, 15cm is hard to hammer flat, and 7 or so is the smallest you can work with without risking fingers.
Thin sheet steel for hand-guard. The amount and thickness depends on what style sword you make.
Solder to attach hand-guard.

Tools:
Bench Grinder
Anvil or anvil like thing
The biggest hammer you have (short of a sledge. I use a 5lb-er)
Sandpaper of varying grits
Pliers
Optional tools:
Whetstone
A Dremel or other rotary tool makes polishing much quicker...
A can of water

Requirements:
Yourself
3-4 hours per sword
A template for a sword is a good thing to have. Making them by feel is hard, but possible.


Risks:
Burns - even though we are not using fire, sanding and grinding metal makes it get very hot. Good luck not getting burned, I aint managed it it yet.
Major Abrasions - you have a rough surface spinning. It could hurt.
Cuts - Never mind, you'll get hundreds of small nicks by the end of it, nearly guaranteed.
Bruising and broken bones - a 5lb mallet can hurt if you miss the nail, hence the pliers.

Making it is dangerous, and if you sharpen it you could probably seriously injure someone. I'm not responsible for what you do.
Enough of that, you get the idea, it isn't safe, but it is fun....

Comments

[ngong0]

I just got the same tool as a gift yesterday and am looking for projects to use it on.

[sdfgeoff]

These tools are great for starting, but working on steel like this, even small grinding takes a long time. You're better off working with aluminium unless you are just adding finishing touches.
Myself I have a bunch of 1mm and 2mm sheet aluminium that I regularly make pendants out of. I'll have to make a ible on that sometime.

[LunaSweetBlood]

What if you don't have a bench grinder? Is there a head for a dremel that would do virtually the same thing?

[bf1828]

Thanks for this instructable after reading it I just had to have a go.
I've posted a pic of my first but by no means final attempt made using the recommended 4" nail.
Bit rough I know but the only way is up from here.
Pommel was a bit of a challange so any ideas on making a better looking one would be gratefully appreciated.

[bf1828]

I've now made a shield for the sword so this is how they look together.
Thanks again for the inspiration

[curvy77]

for easier engravings leave the blade blackened and start from there. since ur doin somthing small you could use a stove burner or blowtorch to heat up the metal and make it easier to hammer down. also if you ever want to make a great sword nail heat up 2 nails till both turn mid orange or low yellow color( extremely hot!!! be carful!!) then hammer ends together (u judge the length) and one u can lift the super heated metal without them seperating give it a few more good whacks and cool rapidly. also use a small dremer or metal file on the edge to give it a good sharpness.

[sdfgeoff]

Leaving the metal blackened does indeed make the engraving stand out more, but does little to improve my own inaccuracy with the tool!

Interesting idea to join two nails, I hadn't really considered that. But then the whole point of this ible is to let people try metalworking without any kind of high-temp generating device (forge, gas torch etc). Still great to know, and I may well try this at some point.

[curvy77]

to help with ur inaccuracy you could make a little paper design over the blade and ,after cuttinging them out, use the holes as a sort of trace path. i did this on my knife and worked well(though mines a bit bigger lol). as for the cold metal work you can try metal folding..... might work.

[yoyology]

You could try etching instead of engraving for blade decoration.
Etching Knife Blades
Etch a Family Portrait (he's doing aluminum, but says it will work on steel)
Etching On Tin Using Crayon-Technique

And here's an 'ible on How to do engraving easy and make it look good. :-)

[spiderham]

Those look great. Here's one I made some time ago. it's not up to par with yours, but I enjoyed making it.

[sdfgeoff]

Out of interest, what did you make the hand-guard out of, and how did you cut the slot for the blade?
Looks great, mine aren't exactly museum pieces either.

[spiderham]

It's a flat washer from some throw away electronic devices I scavenged. It just happened to be the right size to fit over the tang. However, Tinplate Girl has a video on making decorative punches out of concrete nails. I think that might be your best solution for making the holes on your guards. I used a bit of solder on the tang side of the guard so the hilt would hide it.

[sdfgeoff]

Thanks

[curvy77]

to minimize burns or heat pain one should wear thick gloves (gardners gloves will work) and long sleaves. very nice design and work. and remember just cause you dont use a fire to make blades dosent mean its not forging. i have made a few things cold smithing and they turned out fine. the fact that it takes so much time to make one sword means you put great effort into it. Well done!!

[Biggsy]

This is actually kinda awesome, I like it well done... I don't have the patience to make one, nor the tools i suppose... :D

but anyway great work and a well rounded instructable, a high five for you