This is a sword i made for a good friend a couple years ago. It's one of the few i've taken pictures of most of the process of making it. Usually i just zone out and go at it. This sword took me about a week of working late nights after my day job to make.  There are many different ways to make swords, this will show you how i made This one.
  The process of stock removal in blade making is more modern.  With the right materials these blades can hold up pretty well, but the ones i make are mainly for art and decoration, tho. they will hold up to some abuse and are able to be handled.  The quality of your sword all depends on the materials you use, the design you make, and the time your willing to put into it.
     I've been building on my sword making skills here and there since i was younger. I started out with a hack saw and a file. One day I'd like to make my own forge and actually Forge swords, but for now, this is my method.

Step 1: Safety, Materials and Tools

                                                              Safety First!

Before you begin any project remember to protect yourself. Wear Eye Protection, Wear Gloves, and Wear Hearing Protection with loud tools. When welding make sure you use a good welding helmet and thick leather welding gloves, and ear plugs arn't a bad idea, hot sparks in the ear really hurt. Long sleeves or a welding jacket are also a good idea.

                                                             More Safety!!!

This method uses grinders, a welder and deals alot with really HOT metal. Be sure to be AWARE OF YOUR SURROUNDINGS. Work in a ventillated area.  Make sure there is nothing flamable in the area your working in. sparks will fly everywhere and anywhere. Keep a fire extinguisher handy just in case. Also a bucket of water helps to cool pieces your working on because if your welding it, or grinding it, It will be HOT. use pliers or thick leather gloves to pick up pieces that are hot and cool them in water if you need to handle them.

Materials, most of which are pictured below, include:

-1 - 2" x 1/4" x 3' steel bar -( for the blade)
-1 section of 1" x 1/2" steel bar -( for the crossguard) 
-1 section of 1/2" round steel stock -(for the claws on the pommel)
-1  1 1/2" round x 1 1'2"long  section of round steel bar -( for pommel)
-1 large nut, a little smaller that a trailor hitch ball nut -(for pommel)
-1 old claw foot glass insert ( could probably use a marble or something- (for pommel)
-1 piece of aluminum tubing/pipe, that the glass will fit tightly in, and will fit tightly into the nut used for pommel.
-1 piece of hard wood for the grips of handle.
-2 or 3 small machine screws and nuts for countersinking through wood grips to metal handle part of blade.
- vinyl or leather for wraping the handle.
-quality wire to wrap on handle.
      Your materials may vary depending on your design. This is just basicly what i used.



I use a wide variety of air, electric, and hand tools.   The most expensive tool you could need in this project is a Mig welder.  Your project can be as elaborate or simple as you want depending on your design, budget, and what you have to work with.
   Here are some of the tools I used in this project:

- workbench with a vice.
- 4 1/2" electric grinder with cutoff wheel, grinder wheel, and sanding disc.
- air angle grinder with 36 - 80 grit discs.
- air dual action sander with 80 - 400 grit paper.
- die grinder with varying deburring bits.
- drill and drill bits.
- Mig welder.
- Files varying in size, shape and, courseness as needed.
- hammer, and punch chisel set.
- bench grinder.
- sand paper varying from 80 - 800 grit. and a backing (sanding) block.
- polishing wheel and several courseness of rouge.
- Dremmel with small cutoff wheels, small deburring bits, and pollishing bits for small hard to get areas.

Other common small tools may be usefull like pliers or vicegrips.

<p>I, think most though not all of your techniques would be worth using in making battle ready (fully functional) swords too ;) and those who say other wise do some research before you criticize no one likes a smart ass and knowing something and thinking you know something is what makes you wise or a smart ass (Ergo the time spend in researching something).</p><p>I really think being of German heritage (much as my self ;) ) you and your friend would be interested in the ulfberht sword/Swords I will include a very tantalizing and interesting URL link below of a Documentary on You Tube:</p><p><iframe allowfullscreen="" frameborder="0" height="281" src="//www.youtube.com/embed/YVSsRunJ2K4" width="500"></iframe></p><p>Although the information I am about to share wont means much to you at this point unless you watch the entire documentary I will put it down here any ways feel free to read it before or (better) after the documentary ;)</p><p> I have a bit of very interesting information courtesy from the Jewish Torah no less (I have a lot of time on my hands and love to research well what ever I can LOL, that I believe comes down to a part of our German genetics as well as inventing and re-inventing other or new ways to accomplish something).</p><p>well first of I only turned to the Torah as we were all taught in church that the Torah is THEE actual Bible and that all Bibles originate from the Torah of course as with such things even the supposed original Torah to my surprise have many versions thus I can not give you proper information on the version I studied as at the time I did not know, I need to pay attention to the version after all it is said to have been written through guidance by GOD HIM SELF thus: No one is suppose to add ; move or remove any part of it so there can thus be no other versions of it or so I thought. Any ways I do believe it may have been either the Cabal or Qlipothic versions. Now with that out of the way:</p><p>I have read the whole Genesis story, according to that version after Cain Murdered Abel for again (it is documented several times through the story) trying to rape his step sister (progeny from the Union of Eve and the &quot;serpent&quot; / &quot;Red Dragon&quot; as Cain called His Father and also the Identical twin of Cain) and they have according to the Torah &quot;Yellow hair like young weed and Eyes as blue as the Rivers of Eden&quot; / White/Light Gold Blond Hair and Blue Eyes. any ways moving </p><p>on after Cain killed Abel both he and his sister Naamah fled from Eden to join their mother in the outskirts of Eden and because both of them rekindled their blood line through a series of rituals (which is way to dangerous to mention here!) Cain`s Father &quot;the Red Dragon&quot; / Cathong the Vampire God of Blood and Blood Magick taught his children various skills Cain was taught &quot;the life of Metals and how to bend and shape them&quot; the first ever made metal tool was a Black Smiths Hammer that Cain Fashioned in order to more easily shape and bend all the other metal tools and crafts, Naamah was taught &quot;the power of Vibration and Frequency&quot; Lilith seeing the increasing sadness of Naamah as Cain and Cathong were bonding more over &quot;manly things&quot; / &quot;the art of tactics and craft of warfare&quot; Lilith decided than to teach Naamah &quot;the Art and Trait of Music ; Fashion and seduction&quot;.</p><p>Now, it was not GOD who &quot;cursed&quot; Cain (yes, immortality is such a curse every Dick ; Tom and Harry with a basic understanding of Magick mess around with such forces for exactly that &quot;curse&quot; not to mention how many Magus and Magisters Occult Experts most with Big Generational REAL DEAL Magick works in their family libraries strive for this!) anyways, it was Cathong who bestowed immortality upon Cain ; Naamah and Lilith!.</p><p>With that said pay attention to the documentary and you will hear a couple of very interesting facts being mentioned: </p><p>1.) The metal used in the actual sword and that is made by the same individual for Arabia CAN NOT BE DUPLICATED EVEN TODAY WITH OUR UNDERSTANDING OF METALS AND THEIR MOLECULAR STRUCTURE!</p><p>2.) The SAME PERSON made Swords for the Vikings and SEVERAL HUNDRED YEARS LATER also made Swords for Arabia! that means the person obviously would be SEVERAL HUNDRED YEARS OLD! ergo IMMORTAL.</p><p>THUS my Conclusion is this:</p><p>Cain Having Immortality (and is said to have become a Traveler of the world) is a trained Black Smith with a deep and obviously Magickal understanding and grasp of Metallurgy and Magick with other words using his Black Smith Skills mixed in with his understanding of Magick and who knows perhaps Cain and Naamah exchanged their skills between them both thus giving Cain the understanding and ability to use Vibration (Vibroturgy is what the Illuminati calls the skill) ;) which is hinted too by the Scientist who analysis and tested the Actual Swords metal compounds.</p><p>With other words: Cain used his Black Smith Skills to forge the sword but than turned to Vibroturgy to literally pull the Molecules of the metal closer together and changed their molecular / atomic structure to permanently fuse the metal together as one, while also ensuring it will remain able to bend and so achieved a sword that is even to this day still quite pristine and fully functional.</p><p>Vibroturgy Defined (as by the Illuminati University of Lux Nox Aeturnus) :</p><p>Vibroturgy = The Ability to produce sound by natural (mouth/vocal cords) or</p><p> Fabricated (electrical / magnetic) means to change the frequncial</p><p> level and vibration of a substance and/or item in accordance with</p><p> but not pungent to the Laws of Physics and the Universe.</p><p>P.S.</p><p>I do not belong to the Illuminati however I have proven my self through the </p><p>understanding of their codes and puzzles which is in line and only accomplish able by my own personal Blood line / Genetics through my own personal Linage , thus granding me full access to their university: Lux Nox Aeternus.</p><p>The Free Masons even have a Loge dedicated to Cain and a Golf Course called &quot;Two Balls and a CAIN&quot; not Cane as one expect the word to be spelled.</p><p>Also, Cains hammer was found by Archaeologists and is on display in Britain as well (of course they don't say it is Cain`s Hammer, only that it has been dated as the earliest metal hammer)</p><p>In,closing:</p><p>I use Magick to announce it being the Magickal CRAFT not Magic as in the Magical ART (Illusionism / Mesmerism) like you see on TV so don't haggle nor patronize me over my word usage!</p><p>Also, as you can no doubt pick up I am not christian and never ever will be! I have done too much research on it and other religions and can not comply with what christianity stands for ; symbolize and the vile ; disgusting manner christians conduct their lives and actions.</p><p>I am an Independent Polytheistic Magickal Practitioner with Gravitation towards Paganism (the True original Religion all others are/were based of off according to religious scholars and my own research) it is also the REAL Religion and Tradition of Europe/European Blood Lines and I also Gravitate towards Ancient Egyptian Magick / Khemetic Magick. (Khemet = The Land of BLACK SAND /</p><p>The Most Fertile Sand known and thus the Bread Basket of the world. Of course before the entire polarization Shift occurred changing the Nile Rivers location it flowed and so turned Egypt/Khemet into the dessert it is today)</p><p>If you wish to know more in detail about your Blood lines / Heritage and the TRUTH of your Germanic &amp; European Genetics feel free to leave a comment / reply here behind this comment stating clearly your interest and true intention of wanting to know more and we shall take it from there (The same goes for your Lady Friend and whom else may be interested of your friends circle) of course should they also harrken back in genetics to Europe ;)</p><p>Be well and much blessings my fellow Germanic Brother.</p>
<p>looks really nice! I'm just wondering, hows the balance? because that pommel looks way too small to counter that big a blade</p>
A sword needs to be a sword, not just a pretty bit of metal. There is no doubting your ability to fashion a pretty bit of metal shaped like a sword from a piece of metal but really unless you are using some knowledge of metallurgy they are just decorations.<br><br>The Japanese used high carbon steels, about 1.8 - 2.00%carbon. They covered the blade with clay and then exposed the edge. When the sword was quenched it hardened the cutting edge while the main section remained tough due to cooling slower. <br><br>The Damascus blade relied on controlled cooling by plunging the red hot steel, that matched the colour of the setting sun, through the body of a Nubian slave.<br><br>English blades were stretched and doubled over then hammer rewelded a few times to give the strength of wrought iron.<br><br>And so on from using the urine of a red headed boy to quench the steel to using the urine of a goat fed only on ferns.<br><br>Unfortunately your's seem to be just shaped out of any old steel, with no attempt to turn the pretty steel thing into a real sword.. <br><br>Not withstanding - they are well fashioned and look good.
Actually you are mistaken about the Japanese, Damascus, and English blades. <br> <br>There are multiple styles of Japanese swords, but most of them contained about 50% plain Iron, and 50% steel(known as tamahagane). The &quot;legendary&quot; folding/welding technique was meant to homogenize the Iron and Steel, giving the swords the edge holding capabilities of Steel and the flexibility and toughness of Iron. Also some used a core of Iron with steel plates forge welded along the outside of the blade to make the cutting edges. <br> <br>Damascus blades get their characteristics from their steel as well. They were made from what is now known as Wootz Steel, which again is a combination of steel and iron. Also there is no evidence of quenching by driving a sword through a slave, and for good reason. It would ruin the blade. Also, slaves were much too expensive to do that with. <br> <br>Now as for English blades, they primarily used blister steel, which is of an inferior quality from Wootz steel. They also would combine the blister steel with plain Iron to add flexibility and toughness to the blades, and would fold, or twist or both to combine the two. Also while it's probably possible to get an ok quench from urine, it still wouldn't be as good as plain water or oil. Most likely the urine was used as an etchant, due to ammonia content.
awesome work .....i too started making swords with a hack saw and a handfull of files. what a lot of ppl dont realize, that a quallity file well maintained will remove a lot of stock without a whole lot of effort. Ive always been a blade nut...so many knives i lost count, 6 swords, and a few battle axes. some i made and some bought. i wish i had your detail skills. soon i`ll be posting my hand files brass gears for the steampunkers, would have been easilly done with my dremal, but like i said, ppl would be amazed at what a great file can do.
does this sword actually cut or is it just to llok good in your living room or over you chimny
Beautiful work... I have a wall hanger that looks similar, good choice in design.
you seem to be quite gifted in blade making. i applaude your skill. have you ever tried making a blade as tall as a man i.e 6ft? i tried but it didnt turn out exactly as planned and i have to crop it down. any tips?
Nice work,,I have made a broadsword years ago not as pretty as yours,I used leaf springs from junk yard very cheap but better stock than what you will find at homedepot.for the moey you get about 5 leaves per spring assembly.a simple forge can get it hot enough to straighten and will take major abuse.once again Deathatsix very nice work.
I actually have a bunch of leafsprings. doing collision repair every so often we have to replace some and i grab what i can. tho reciently du to needing some money i scrapped some. still have some just havn't had time to work with it.<br> Good advice! and thanks for the compliment.
This is great - especially if you don't have a forge of some kind or something that can be used as to heat the steel until it can be forged. This thing can be tempered before you finish it right?
Sure it could be tempered and heat treated before completion. I don't yet but that's just due to lack of the equipment I'd need. There is more then one way to get the results but that's easily searched through people with experience.
Very beautiful! You make wonderful blades, your knowledge and photos would be appreciated at http://sinza.forumotion.com/forum.htm :D I am a member myself and it's a pretty cool place. If you join, tell 'm CCK sent you ;) Wonderful work, I love it!
Thanks. I'll check it out.
Cool, thanks! Seriously, add your pictures of anything you've made and the admin will be sure to bump up your rank ;D
Can you make me a survival knife
i probably could make one. there's alot of them out there and it would probably be cheaper to find one that suits your needs somewhere else. if you can't find one out there then i guess i could make you one but depending on style, size and other stuff it could be pricy compared to something premade.
damn in your slideshow i posted a comment saying you made these? and know i am amazed how the ........ do you do it???? you make sick swords and axes.!!! although i do have an idea for your next if your interested in it or not its up to you.. how about an axe similar to the ones you make but you have a sword on the bottom kind of like a sword-axe?? like or not reply your thoughts on this idea thaz
most impressive!! especially your expertise with a dremel tool. I always end up with divots in the metal when I try to use one for fine detail work, from it catching and skipping along the metal. Very nice
Thanks. It takes some patience, and alot of moving yourself or the blade to the right angle.
yeah, so... one of those swords looks really familiar... http://failblog.org/2010/07/06/epic-fail-photos-conan-the-barbarian-fail/
That was alot more then i needed to see.
This is cool, but making a sword by stock removal does not produce the strongest blade. To make a good sword, you should forge it and use certain types of steel.
Thanks. And i don't disagree that forged swords are stronger.
Forged swords may be stronger, but wall-art needs little strength. This is a great route for people who want purely decorative swords, and I'd bet much, much cheaper than forging. Deathatsix, I like the look of that blade. How many other swords have you made by this method? A slideshow of your work might be merited.
Much appreciated. and i've already made a slideshow with some of my works, though this would probably be my mose elaborate work to date. it can be found here: http://www.instructables.com/id/Swords-Daggers-and-Axes/
Checked it out. They're pretty good.
I do agree with you 100%, I just thought I should point that out.
This should Be featured ,it's quite amazing, Great work. If i could weld and all that I'd make a fantasy sword such as this.
i don't know if it should be featured. i just hope that it's understandable to people who would have an interest in something like this. but Thank you.
This is quite impressive! idk how much you could sell that for.
Not sure. i gave it as a meaningfull gift to a long time friend. i was told it would be worth a bit. Thanks

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