UPDATE!!! I WILL BE RE-WRITING THIS 'IBLE SOMETIME IN THE NOT-SO-DISTANT FUTURE. SINCE IT'S PUBLICATION, I HAVE LEARNED A BETTER WAY TO MAKE THESE.
Here is my Instructible on the making of Bo-Shuriken. Traditionally, they were made of anything readily available; nails, needles, or rods of metal. I'll be showing you how to make them out of nails.
Materials are as follows:
Bench or angle grinder.
Cup of water.
Propane torch(or other gas).
If you like to hear things, wear earplugs
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Step 1: Cut Off the Head
Begin by cutting or grinding the head off the nail. If you cut it off, grind what's left smooth.
Step 2: Sharpen the Tip
Grind the tip to a needle point. Make the angle fairly steep. Dunk it in the water every few seconds. Don't burn your fingers.
Step 3: Harden the Tip
This part is optional but recommended. Take your torch and crank it up high.
Using the pliers, stick the tip of the nail into the flame. Hold it there until it is a bright orange color. Immediately stick the tip into the water and pull it back out again. Do this over and over again until it stops hissing.
Step 4: Blacken the Whole Thing
Again this is optional but it does make the shuriken look cool. Do the same as step 3 this time only heat it enough to blacken it along the length. Once you're happy with the finish, drop it in the water. When it is cool enough to handle, you are done with the making.
Step 5: Throwing Your Toy
First off, NO throwing at animals, private property, or little brothers. PERIOD! It is hard to properly explain the movements needed for throwing bo-shuriken. The best I can do is say that you move your hand like you are karate choping the air. See the pictures for help. if you still need help, go to www.secrets-of-shuriken.com.au. If you need a target, tape 3 or 4 layers of cardboard together and paint or draw a target symbol on the cardboard. Or if you have an ugly old shed you could throw at that. Now go toss that toy!
Step 6: The Sheath...And Done!
It isn't very usefull without a sheath, is it! Almost forgot! The sheath is really simple. Take the pipe cutter and cut the pen barrel so about 1/2 inch of the shuriken sticks out. Now you're done at last. Teach your friends to make them. Be careful. And most of all have fun!