Metal Sword (of Doom)


Introduction: Metal Sword (of Doom)

About: I make things.

Have you ever wanted to have a nice sword? I have. Now you say, "Why don't you just go buy a plastic or wood one from Walmart?" Because the plastic ones break and the wood ones do too, not to mention they're made in China, which means the workers are underpaid, they probably have lead paint, and they're just plain crappy. You can make a good quality wood one yourself, which I have done, and it works, but I've always wanted a metal one. So I finally decided I couldn't wait any longer so here it is!

Step 1: Tools

~Something to hammer on, like a piece of wood
~Cinder block or some raised object, if you want your sword curved
~Sandpaper 100 grit or more
~Hacksaw blade, preferably one for cutting metal
~Hacksaw handle


Step 2: Materials

|---------Sword stuff----------|
~1 10' piece of 1/2 inch metal conduit -$2 at lowes

|---------Handle stuff---------|
~Thick stiff leather -I had it lying around -$7 at craft store and you'll have alot left over
~Thin leather -I had it lying around
~gorilla glue or pine sap if you want it to be old timey -I had it lying around -$3 for bottle
~some sort of cord, I used hemp -I had it lying around -$3 at craft store

|-----Total for everything-----|
~$15 with a lot left over

Step 3: Cut It Up (Muhaha)

Tools needed
~Hacksaw blade
~Hacksaw handle
~High-performance piece of moldy wood

Materials needed
~Metal conduit

You want to cut it the height from the ground to your bellybutton so if you hang it from your belt loop it won't drag on the ground. My hacksaw handle didn't show up so I had to use my hand. It will take 2-5 minutes with a handle and 5-15 minutes without a handle (like me). Then sand both ends with your sandpaper until it's nice & smooth.

Step 4: Smash It.

Tools needed
~High-performance piece of moldy wood

Materials needed
~Cut conduit from last step

Now for the fun part, hitting it. If you care about your hearing, wear earmuffs\earplugs. Make sure to hammer it evenly on both sides so it doesn't bend to one side and to keep hitting it in a straight line so that it doesn't start to twist.

Step 5: Give It Curves

Tools needed
~High-performance cinder block

Materials needed
Hammered conduit from last step

Step 6: The Handle - Part 1

Tools needed

Materials needed
~Thick leather
~Gorilla glue
~Hammered, curved conduit

First cut out 2 pieces of the thick leather 2" by 3" with rounded corners. Then, use the knife to make a hole in the middle of the leather. Then using the scissors widen the holes by cutting small slits out from the center as in the second picture. Make sure the holes are just big enough and small enough to be a tight fit. Slide both pieces to the point where the "blade" meets the handle. Then finally use your selected adhesive to keep part 1 and part 2 together. Also use the adhesive to keep the parts in one spot.

Step 7: The Handle - Part 2

Tools needed

~Thin leather

First, cut a 6" wide piece of leather as long as the handle end of the sword. Then, with the scissors, cut several holes 1 to 1 1/2 inches apart on the handle length side. Make the holes 1 inch from the edge starting 1/4 inch from the end.

Once your leather has been cut to the correct size and filled with holes, well not filled but when you poked the necessary holes, use your cord to tie a knot through and around the leather so it's tightly bound to the handle as seen in picture 1. Next, with a "running stitch", tie the leather to the handle as tightly as you can. DO NOT CUT THE CORD. Once you're done, wrap the now bound leather around the handle (picture 2) and use a clove hitch to tie the end of the leather at the end of the handle (picture 3). Then use a clove hitch every 1 to 1 1/2 inches up towards the hand guard. When you get 1/2 to 1/4 inch from the hand guard, keep tying the clove hitch repeatedly until you get to the hand guard (picture 5).

Step 8: You're Finished!!!!

Congratulations! You have completed making you're very own High-Quality Metal Sword (of doom). I hope you had as much fun reading this instructable as I had making it. If you do make your very own High-Quality Metal Sword (of doom) please post a comment so I can add you to the Ultimate list (of doom).

Step 9: The Ultimate List (of Doom)

People who have made The Metal Sword (of doom)

-dwhp-If you want to see his, it's in the comments
-lotrsam11 also in the comments
-vd8drum, just click the link to see his



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    72 Discussions

    well that's nice and all but the thing is its just as easy to build a forge and pound out your own REAL sword, granted it takes practice, but so does everything else, just make sure to use REAL blacksmith-ing coal if that's the route you want as a fuel source.

    if you wanted a metal sword you can buy one off the internet. I got a really nice one at website called swords 4 samuri

    Conduit is used to house wires. It keeps them from being cut or mangled.


    You sound like a funny guy, but i have to tell you that unless you pressure welded the sides of pipe together (and even if you did) it would break or bend in a fight. Especially if that metal aluminum? You should go for either a mild steel or iron bar or a strip. That way its easy to shape but you can make it stronger by tempering.

    I have done something similar in the past, but had forgotten about it.  Thank you for reminding me in such eloquent language!

    Possibly helpful tidbit:  one source for the "metal conduit" is ski poles, especially ye olde ancient aluminum ski poles, which can be very long.  It is quite easy to remove the paint; I use a bench grinder with a wire brush on it, but a high performance wire brush (with handle) or sandpaper would probably do the trick too.

    This is honestly amazing! Just what I was looking for! I was planning to make a movie but I'm in Britain, and there are veeeerrryyy strict weapons laws in the UK. I may make some adjustments to your original plan but still thanks for the amazing instruction lol XD

    I've started to make this, but with a wood handle and flat stainless steel blade! Almost finished

    I will give you credit good idea for a play sword but don't insult sword making by calling a smashed metal pipe high quality

    7 replies

    Maybe you should research what swords were actually used for when invented. They were not made to gloriously hack enemies in to pieces with a few swings, like the movies often portray. The first swords in many areas were made of bronze, and although a blade like edge could be applied, they were hardly good for cutting. They applied blunt force trauma wounds when used, breaking bones. Much like their brother the mace. In lieu of this, a metal pipe hammered down to give less wind resistance when swung properly, is a nice representation of the aforementioned. It is no insult to think of different materials or paths to use when making something that is already widely used, that's how we humans are to the point we are now.

    True of many swords across history, for sure, especially in eras in with lots of armor. A bronze-age short-sword wouldn't hold an edge for very long during "intense use" . Scottish claymores, along with many of the more ornamental African swords or Aztec war clubs with obsidian blades mounted down the sides  would also be good examples of this kind of weapon.

    The katana, tho, would not be. And that's what this sword is clearly modeled after.They were designed for cutting. Folded steel blades stay sharp as the layers of softer steel wear away faster than the harder steel, creatiting a virtual microscopic sawtooth. The martial arts which use them are all centered around powerful cutting strikes and practice. They were owned by high-ranking members of society (especially in times where they forbade swords to lower classes), and saw a lot of upkeep. This weapon was not a bludgeon.

    Pounding conduit into a sword is a really neat idea, and gives a nice effect. But if you're going to call it "high-quality", it'd be nice if it were at least solid and had no hollow bits.This is without a doubt the coolest toy sword I've seen in a long time, but as for a real sword you'd probably still be better off with a leaf spring.

    Well, it actually is alot higher quality the anything you'd buy in non-specialty store.

    Not really. A low quality forged blade is still better than a smashed pipe. Although your idea is good, I stand by limpach that it's not right to call it high quality.

    I think he's comparing it to the 20 dollar crap you find on websites. These smashed pipes are better than those Stainless steel machine-made stuff.

    Not really. A heat treated, machine made stainless blade is still better than a smashed pipe.