Introduction: Real Metal Looking Sword Out of Pallet Wood

I have always wanted a sword, since I made a viking shield it needed the Viking sword to go with...

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Step 1: Processing the Stock

Picture of Processing the Stock

I am using beech pallet wood

Cut it to size

Mark the middle

Step 2: Forging

Picture of Forging

Draw out the shape of sword and shape it with chisel or wood plane

Hollow out the fuller with router or chisel it with gouge

Make Bevels using the wood plane

Step 3: Cross-guard

Picture of Cross-guard

I have made through mortise hole to attach cross-guard to tang

Step 4: Make It Special

Picture of Make It Special

I made my own design on pommel and cross-guard and also carved +ULFBERH+T inside of fuller

Step 5: Handle

Picture of Handle

I Assembled the whole sword, sand it and wrapped it with cord

Step 6: Paint Job

Picture of Paint Job

Paint it with Silver (3 coats) then black from far away

first step will give you the look of cast iron

And then scrub it with thinner on piece of cloth do get steel look and aged finish ( but don't overdo it because you will remove all the paint)

Step 7: Sword to Be Proud of :)

Picture of Sword to Be Proud of :)

This build came out perfect and I am super happy :3

Comments

Rich_Limburger (author)2017-12-12

cool sword, job well done, nice instructable. i love beech wood, i've made 2 double edged pratice daggers from it for my daughters. That way we can practice safely knife techniques together if they feel like it.

PhillL1 made it! (author)2017-03-08

I didn't spend the time, effort, or talent you did, but I had fun making my version. I generally don't try for accuracy, just enjoyment - so don't analyze the designs!

BenjaminB98 (author)PhillL12017-08-21

That is amazing

Epic Workshop (author)PhillL12017-03-08

You shiting me bro... IT LOOKS FREAKING AWESOME :DDD
The fun is what is keeping me doing these projects :)
I love the hilt design beter than mine :p
Only if you give the fuller some more time it would look even better :) the rest looks great :)

PhillL1 (author)Epic Workshop2017-03-09

You're too kind - TELL ME MORE !!

$1.58 Home Depot fence picket.

rjamendola (author)2017-03-03

Really, really amazing! Congratulations! I'm delighted with your work, and despite my limitations, I will try to do this sword. Do you mind if I contact you via Instagram to ask you for help if I needed?

Epic Workshop (author)rjamendola2017-03-03

Thank you very much for nice comment bro :3 You definitely need to do it :)

I don't mind it at all, you can contact me any time and I will be happy to help :)

Cheers

Moris

Fathomlis (author)2017-03-02

Love this! So epic! Well done really! and this project will help so much if I want to build something of the same kind. Thanks bro!

Epic Workshop (author)Fathomlis2017-03-02

Thank you very much for nice words bro :) you can contact me via Instagram anytime :)

panchirulo (author)2017-03-01

This is amazing, you are the number one +, congratulations. Esto es impresionante!!! Eres el numero uno +!!! Felicitaciones (in spanish)

Epic Workshop (author)panchirulo2017-03-01

Thank you bro :)
Muchas gracias hermano :)
I was in mexico so I know some words ;)

rvail136 (author)2017-03-01

superb work. Wouldn't have known it wasn't real if I'd just seen the pictures. Well done sir.

Epic Workshop (author)rvail1362017-03-01

Thank you very much for nice words. I was going for look of like "my grandfathers sword" and I think that I nailed it :)

andrewv71 (author)2017-03-01

Just a few more questions, sorry. What type of planer are you using that is taking wood from the middle of the sword where you cut the fuller? And what is it you used to treat the grip? Thank you in advance.

Epic Workshop (author)andrewv712017-03-01

Please don't be shy.. ask away I love to help :) You can also contact me anytime on Instagram in private chat if you want.

For fuller I am using router plane, gouge chisel and scraper to smooth it. And also a sandpaper.

For grip I poured some linseed oil, mainly to get darker color and burning is for getting rid of this rope things and to darken it to look used :)

If you need any more help you know where you can find me :)

Cheers
~Moris~

andrewv71 (author)Epic Workshop2017-03-01

Thanks man! I do not use instagram. I think I have it just do not use it lol. What brand router plane is that? I cannot find one on the website for my hardware dealer. Thanks again Moris!

Epic Workshop (author)andrewv712017-03-01

Ah ok I just have so I can be in contact with my audience if they need any help :)
It is Veritas hand router plane :)

And when you make the sword be sure to send me some photos I would appreciate it :)

Have a nice day
~M~

AF6YS (author)2017-03-01

Echo the Excellent craftsmanship!

Epic Workshop (author)AF6YS2017-03-01

Thank you :)

ERICOSCAR (author)2017-03-01

Dear author

Excellent craftmanship !

You should bring this to the annual medieval week on island of Gotland in Sweden.

But one thing makes me a little suprised.

On the handle you have carved in a christian symbol, crossing lines with a P.

Viking-age was a little before christianity had reached viking-land, when the German emperor provided the missionary Ansgar to christen the north, mainly the present Sweden, he immediatly came in to trouble with the viking pageants.

That would place your sword more in to medieval days when chrianity had a strong foot here.

Anyway a very nice piece of craftmanship !

Epic Workshop (author)ERICOSCAR2017-03-01

And yes I carved that symbol because of simple curiosity.
I saw it in one movie of which I don't remember the name :/

Epic Workshop (author)ERICOSCAR2017-03-01

Thank you for kind words :3
I think that travel to gotland is not possible unfortunately :/ I am from Croatia...

Finnaly somebody told me what that sign means because in video description I asked what is meaning of that symbol :)
But on other side of sword I carved rune Mannaz which I use like my makers mark which means to me a lot because Lord Of the Rings :D

Does that symbol has a name for it so I can research more about it or is it from some order.

Thank you one more time for nice comment :)

~Moris~

XaviOrin (author)2017-02-18

Awesome 'Ible! I am purchasing new wood working equipment and needed a project and this is definitely something I'm going to try out.

Epic Workshop (author)XaviOrin2017-02-19

Thank you, yeah you definitely need to try to make it, if you make it please send some pictures :)

How and where to get the templates to make a sword?

Congratulations on the beautiful work!

Sorry for the English, because I'm Brazilian and I'm using the translator ...

Thank you bro, your english is great :) I originally didn't used template, I went to web and searched for viking sword measures :) If you want send me a message on Instagram and I can help you during the build :)
Take care and have a nice day
~Moris~

ghostrider2k (author)2017-02-28

I think its great but I work in steel and brass. But it is a good facsimile. Well done on your hard work.

Thank you bro :) maybe make one in steel with brass inlay :D

Eli9232 (author)2017-02-28

Ah, yes! An Ulfberht! Wonderful work.

Epic Workshop (author)Eli92322017-02-28

Thank you :3

Eli9232 (author)Epic Workshop2017-02-28

Yes, It is absolutely beautiful.

Epic Workshop (author)Eli92322017-02-28

:3 <3

ghostrider2k (author)2017-02-28

"Zeus' son needs more than an actor's painted cloak and wooden sword to protect him..."

srilyk (author)2017-02-28

You should totally use the knock-off Uthberht runes, as a subtle way of advertising that it's a wooden sword ;)

Epic Workshop (author)srilyk2017-02-28

Sry I didn't understand, I think that I used correct lettering, but indeed it would look epic with runes also :)

srilyk (author)Epic Workshop2017-02-28

If you watched that one documentary where they made the Uthberht copy, they talked about how there were forgeries back in the day where they misspelled Uthberht some way (I don't remember and I don't have the time to go look right now). When they analyzed the metal they found that it had an inferior quality.

So if you *also* use the misspelling, it's a subtle way of saying, "This isn't actually Uthberht quality - it's really a wooden sword. And I'm aware of *both* facts and the misspelling is a subtle nod to anyone else who also knows these things."

Epic Workshop (author)srilyk2017-02-28

Yeah I know for that documentary very good :)
I made an ulfberht replica out of wood and I wrote the lettering right way +ULFBERH+T also the original maker used +ULFBERHT+ and then you have fake ones :) but I know the story about legendary Ulfberht sword
Cheers
+Mori+s
:p :)

andrewv71 (author)2017-02-28

That sword is awesome. I just began wood sword making myself. How much should I expect for a table saw to set me back? Also when you spray painted was it just paint thinner you used to age the blade?

Epic Workshop (author)andrewv712017-02-28

Thank you Andrew :) Thats great news, I dunno what saw you want to buy I have DeWalt 745 and it works fine :)
First I sprayed it with 3 coats of silver spray one black from far away and then when dry paint thiner on piece of cloth and rub to get aged look :) Its very simple just dont stay on one place for too long ;)
Cherrs Moris

dukejustice (author)2017-02-28

OK. It is official... You blew my socks off!

I am TOTALLY impressed with your work. And you are so amazing at it that you just "spanked" me into doing something equivalent with the talents that I DO have: I'll build myself a DIY CNC router and create a sword of mine with CAD software and mill it myself.


I can't say I'm as talented as you are, but the end result will be that I'll be proud of my sword and it'll all be with your grace.

Keep up the good work!

Best regards.

Marc.

Hahahahahaha you made my day with this comment :D
When you make it send some pictures here please :)
Thank you once again and see ya with more projects this saturday :D

craftydrayguhn27 (author)2017-02-25

this is so cool I really want to try it. I once saw a documentary about people trying to recreate a viking sword and they and they dipped they hot sword in oil and when they pulled it out it was flaming it was amazing expecially for an Inheritance Cycle fan.

Thank you very much :D yeah I know exactly what documentary you saw haha: "secrets of the viking sword" you can find it on YT,
That process you described is called hardening and when you quench hot sword into oil it bursts into flame and it's very cool :) Pity that I didn't done it myself on my sword. :)
If you need any help with build send me a message on Instagram and I will help you anyway I can :)
Cherrs Moris

DIY Andrea (author)2017-02-21

It looks so real! Great job!

Epic Workshop (author)DIY Andrea2017-02-21

Thank you Andrea :)

allangee (author)2017-02-21

Nicely done! I've heard you can "polish" it with powdered graphite and a rag. The longer you spend on it, the more metallic it looks. However, I don't know if the graphite will then get all over your clothing, hands, etc.

Epic Workshop (author)allangee2017-02-21

Thank you :) Thats good idea, I think that would be messy because when I was drawing with graphite pencils in art school I was like a coal miner after class :D

The Rambler (author)2017-02-20

Absolutely Beautiful.

Thank you my friend :)

BossyRangs (author)2017-02-19

Cool! A real Ulfberht! Have you seen this documentary?
https://www.youtube.com/watch?v=fTlmrAh1oHI

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