Hello everyone! I have just finished one of my coolest projects so far (in my opinion). So my cousin being a blacksmith and me a carpenter, we often like to get together and combine our talents. This means, of course, SWORDS. And, me being of Egyptian decent, I decided to make one of the sexiest, and most well designed swords know to man: The Khopesh.
Over the course of two days, my cousin and I both worked on our weapons (his a Bowie knife), one day on the blades and the other on the handles. This Instructables, will be mostly pictures with a little text, however, I tend to ramble and will likely write a 2 page paper in the process. Anyways, enough talk, let's begin!
Step 1: Materials and Tools
Wood for handle (I used rosewood as it contrasted the steel nicely)
Wood Plugs (optional but makes the handle stronger)
Long drum of quenching oil or water
Lots of clamps
Step 2: Flatten the Steel
Using the forge, heat up the steel then unravel it and flatten it like a raccoon on the highway.
Step 3: Sketch Out the Outline
This is pretty self explanatory, sketch out the outline. I just free-handed it from a picture on the interweb onto the worktable using a grease pencil. The overall length of this sword is around 43 inches.
Step 4: Bending
Begin to draw out and flatten the steel, then start to give the Khopesh its curves.
Step 5: Sharpening
Clamp the Khopesh to the table with the blade sticking off then, using the angle-grinder, sharpen the edge.
Step 6: Character
Just to brake up the uniformity, I added a grove along either side of the steel between the blade and the handle.
Step 7: Distractions
Of course, no project is complete without a few quality distractions, and in our case, it was one of my cousins goats getting stuck in a net. We had a fun time getting her out of that one.
Step 8: Make It Holy
I apologize, but I got a thing for puns. Anyways, drill holes in the handle so that you can connect the handles to the blade.
Step 9: Tempering
To temper it I followed the advice of a couple instructables. Of course, tempering is not necessary however, if you plan on using this in battle or as a practice weapon, I highly recommend it. However, be warned, as this is a long sword it can be difficult to temper, and can be curved or cracked in the process, so proceed with caution.
Step 10: Attaching the Handles
Trace the blade handle onto the wood. Then cut it out and get it as close to the blade handle as possible. The next step is to sand down the handle to the thickness and curvature you want, which must be done before the attaching, so any finishing you want done, make sure you do it now.
Then, once you have the wood handles where you want them, Clam one of the wood handles to the blade handle and drill holes into it from the steel side so the holes line up perfectly. Then epoxy that side to the blade. Once the other side is dry, take off the clamps, match the other wood handle to the blade handle, then clamp it and drill the holes threw the already drilled wood and metal handles and into the new wood handle so that the holes all line up perfectly. Then epoxy the other side to the blade as well, clamp it and wait till it is dry.
Once the handle (collective of all three) is dry put a little glue on the wood joiners (little wooden dowels) and hammer them through the handle. This gives it extra strength connecting all three pieces. Next, cut the excess of the joiners off and sand them down to be flush with the handle.
Step 11: Finishing
To finish it put several coats of polyurethane on the handle. Let it dry and you're finished (last one I promise).
Step 12: Le Fin
Well, that's all folks, hope you enjoyed it, let me know if you have any comments or question.
Thank you and God Bless!