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
Step 2: Materials
~1 10' piece of 1/2 inch metal conduit -$2 at lowes
~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)
~High-performance piece of moldy wood
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.
~High-performance piece of moldy wood
~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
~High-performance cinder block
Hammered conduit from last step
Step 6: The Handle - Part 1
~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
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