These are mini swords made from duplex nails. They are super easy to make and can be made with very basic tools. I have found these to be very popular as decorations, little charms, or a small hole could be drilled to make them into keychains.

Please use caution if you make these and wear proper safety gear and work in a safe manner. Injury can occur if done improperly and I accept no responsibility for injuries caused by replication this project.

Supplies

The tools needed are not very expensive and can be found in most hardware stores.

Tools:

Propane torch (I used a propane torch for the first few and use my forge for batch work)

A way to light the torch (matches, lighter, striker)

Pliers or tongs to hold the material

A hammer to hit the material.

Something to hit the material on (Anvil, sledgehammer head, chunk of metal, etc.)

Safety gear (I used Safety glasses, hearing protection, and closed toed shoes.

Materials:

Duplex nails

Optional:

Brass brush

Step 1: Heating the Nails for Flattening

This can be achieved through the use of a propane torch, a propane or coal forge, or even an induction forge. The metal just needs to get to a red heat. The nails will lose the red color quickly but can still be flattened after the color has changed.

Step 2: Flattening the Nails

I found that placing the nail with a flat side up gave the best shape. Even though the red heat has been lost, The nail can still be flattened. It does take a bit of time when done with a propane torch as the nail has to be heated in sections for flattening.

Step 3: Shaping the Nails

Using the horn or edge of an anvil or striking surface, the nails can be given curves to make different shapes of historical and fantasy weapons. After making the desired shape, you should also check the straightness of your sword.

Step 4: Optional: Brassing the Swords

To add some color to the nails, you can heat them up slightly and brush the with a brass bristle brush to leave a layer of brass on the surface metal.

Step 5: Have a Mini Sword Fight

Sadly, I don't have any pictures of this. Me and my siblings got together to clink these mini swords together to somewhat live out our fantasies of being pirates and samurais.