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
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.
Anvil or anvil like thing
The biggest hammer you have (short of a sledge. I use a 5lb-er)
Sandpaper of varying grits
A Dremel or other rotary tool makes polishing much quicker...
A can of water
3-4 hours per sword
A template for a sword is a good thing to have. Making them by feel is hard, but possible.
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....