Step 1: The Design
Once I have decided to make a piece I begin by making several rough sketches. If I am
working with a customer then I use the feedback from these sketches to refine the design.
The Final sketches for this project include the profile view and a full-scale rendering of the hilt
Step 2: Forging the blade
When I begin forging a major piece I write a invocation, on the floor of the shop.
The invocation for this piece is writen in the modified Aglo-Saxon Futhark and reads:
Forged in the cunning fire, honor and duty to inspire.
If you have any questions about this please visit the philosophy page on my website:
The steel I used for this seax is 1095 3/16x1 1/4" bar stock.
For most of my forging I use a 6 lb. hammer
I mark the important demensions on the anvil so I can check the blade while I'm forging it.
In this case the blade is 15" long and 2" wide.
Step 5: Forging the tip
I begin forging by shaping the tip
Step 6: Forming the bevel
Then I draw out the bevels on the edge
Here you can see how I work the bevels back along the edge a little at a time.
Here the blade has been rough forged.
Next I cut the blade from the billet.
I use a roofing hatchet and a 3 lb. hammer to do the cutting.
Then I draw out the tang , refine the shape, and straighten the blade.
Here is the blade after I've finished the forging process.
Step 13: Filing
Once the blade is forged to my liking I begin the filing process by defining the profile.
Then I take the fire scale off using an old farrier's rasp, as the scale is very hard on files.
I continue working the faces of the blade with the rasp until they are relatively flat
and close to the final dimension I want.