How to Make a Sword

About: I have this page to show people that you don't have to be an expert to try to make something, or paint something, or weld something, or design something. Just get in there and try it. Get your hands dirty!...

DISCLAIMER:  Make a sword at your own risk!  I'm just showing you how I did it--not saying you should follow my methods.  I certainly think you should use personal protective equipment (PPE), and follow safe tool use precautions.

 I didn't know ANYTHING about making a sword, and I don't claim to know much more now.  I know that a real sword is forged and advanced blacksmithing and forging skills are required for creating a real sword.

Mine, on the other hand, is based on a hybrid European two-handed double-edged broadsword made from crappy mild steel (low carbon content), and it isn't tempered or anything.  At best, this is purely decorative. 

But, it was FUN to make!

That said, I think it could probably at least be stowed away as a weapon to hack up zombies, should some apocalyptic event should occur.

Hope you like it.  More videos to come!

--Jason Sipe



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    15 Discussions

    Dan TheD

    2 years ago

    That is awesome!


    That is an angle grinder with a zip disc--a really thin abrasive disc. I polish it up with a flapper disc--basically that is a disc made up of flaps of sandpaper.


    5 years ago on Introduction

    Awesome! I've gotta say this video was straightforward and simple, which is what works for me and alot of other people who want to give a hobby like this a try without investing time and money into making their own forge. Good video!

    P.S. It makes me so happy that Pfred cited Rambo, vikings, and PBS. Many kudos to you sir!


    5 years ago on Introduction

    That looks like a very nice Sword and it was very cool of you that you let us know that you are not a Professional Swordmaker. Your video still could provide someone,somewhere with a simple,capable,Inexpensive and effective means of making a sword/knife for survival/simple cutting jobs in case an apocalyptic event occurs and swords/knifes become worth more than their weight in gold overnight due to economic collapse. I've always wanted to make a sword .Have you seen the video of the guy who made the "Ulfberht" Viking Sword ?


    6 years ago on Introduction

    It was OK but Rambo taught me to make my expedient bladed weapons out of old vehicle leaf springs. Spring steel is choice material for such.

    I also do not think you made the tang of your sword right. Your error there will likely cause you difficulties securing your cross guard. What you're making is more of a machete than a sword.

    Traditionally the tang of a sword acts like a rivet (a capstan rivet), axial to the weapon, and the pommel is like a fastening washer,squeezing and holding the grip to the cross guard.

    Real swords are actually quite cunning bits of art. Their simple design is a large part of their attraction. Quite literally to the point objects.

    BTW, it is always a better policy to outpace shambling zombies than it is to stop and hack at them.

    3 replies

    don't mean to be that guy, but not quite right. a tang can be made many different ways for many different purposes. the one you are thinking of is called hidden tang, and works well for smaller swords and knives. he has created a full-tang blade, which offers more strength throughout the hilt. in this case, he would do well to peen the crossguard directly to the tang, and then cut the hilt scales to fit. add a leather grip wrapping and voila!

    You would do well not to try to guess my thoughts. Apparently what I was referring to works rather well for the largest of swords. (explore the link supplied below)

    He would do well to do some rudimentary research into the traditional sword form. This page illustrates what swords are like:

    It is enough to see the shape and how various parts relate to each other at least. There you go 1,000 years of swords. They're all made basically the same.


    Reply 5 years ago on Introduction

    Pfred2, although you do seem to be knowledgeable, your comments come across as slightly arrogant. I made this for fun out of scrap mild steel we had laying in a pile on our shop floor. I built theater sets and props, so my intention was not to use this against an enemy. It was to make something.

    I made the video also for fun--and if someone found it and tried to make a quick and easy sword or machete--great!

    Thanks for the Wikipedia lesson, though!

    BTW, I would love to see a video of the pattern-welded or hand-forged sword, knife, or machete that you have constructed with the precision that your comments suggest you expect. If you post it, I will watch it, and leave positive comments--promise!

    Hey guys, thanks for the comments. I'm not trying to show people how a master does it--just how a regular guy can make something kinda neat.
    I'd love to see the swords you've made!

    1 reply

    not too shabby! not bad for a first attempt, but you are correct, to be combat quality it would need to be forged, hardened, and tempered. you have the basics down, though. simply cut the blank blade out of a slightly thicker material, slightly smaller than you want, forge out the bevels and grind the profile, heat to yellow and quench, then temper, polish and sharpen. excellent work for a non-smith!