Real Metal Looking Sword Out of Pallet Wood

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Intro: Real Metal Looking Sword Out of Pallet Wood

I have always wanted a sword, since I made a viking shield it needed the Viking sword to go with...

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Step 1: Processing the Stock

I am using beech pallet wood

Cut it to size

Mark the middle

Step 2: Forging

Draw out the shape of sword and shape it with chisel or wood plane

Hollow out the fuller with router or chisel it with gouge

Make Bevels using the wood plane

Step 3: Cross-guard

I have made through mortise hole to attach cross-guard to tang

Step 4: Make It Special

I made my own design on pommel and cross-guard and also carved +ULFBERH+T inside of fuller

Step 5: Handle

I Assembled the whole sword, sand it and wrapped it with cord

Step 6: Paint Job

Paint it with Silver (3 coats) then black from far away

first step will give you the look of cast iron

And then scrub it with thinner on piece of cloth do get steel look and aged finish ( but don't overdo it because you will remove all the paint)

Step 7: Sword to Be Proud of :)

This build came out perfect and I am super happy :3

2 People Made This Project!

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54 Discussions

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HudsonR1

2 months ago

Hello from Brazil mate. First of all, congratulations on your project. It's nicely done.
I'm gonna try to make this project as well. I'll start with the blade as well however I've a doubt about the thickness of the blade. I don't have a band saw, therefore I planned to use a planner to adjust that.

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Rich_Limburger

10 months ago

cool sword, job well done, nice instructable. i love beech wood, i've made 2 double edged pratice daggers from it for my daughters. That way we can practice safely knife techniques together if they feel like it.

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rjamendola

1 year ago

Really, really amazing! Congratulations! I'm delighted with your work, and despite my limitations, I will try to do this sword. Do you mind if I contact you via Instagram to ask you for help if I needed?

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Epic Workshoprjamendola

Reply 1 year ago

Thank you very much for nice comment bro :3 You definitely need to do it :)

I don't mind it at all, you can contact me any time and I will be happy to help :)

Cheers

Moris

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Fathomlis

1 year ago

Love this! So epic! Well done really! and this project will help so much if I want to build something of the same kind. Thanks bro!

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Epic WorkshopFathomlis

Reply 1 year ago

Thank you very much for nice words bro :) you can contact me via Instagram anytime :)

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panchirulo

1 year ago

This is amazing, you are the number one +, congratulations. Esto es impresionante!!! Eres el numero uno +!!! Felicitaciones (in spanish)

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Epic Workshoppanchirulo

Reply 1 year ago

Thank you bro :)
Muchas gracias hermano :)
I was in mexico so I know some words ;)

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rvail136

1 year ago

superb work. Wouldn't have known it wasn't real if I'd just seen the pictures. Well done sir.

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Epic Workshoprvail136

Reply 1 year ago

Thank you very much for nice words. I was going for look of like "my grandfathers sword" and I think that I nailed it :)

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andrewv71

1 year ago

Just a few more questions, sorry. What type of planer are you using that is taking wood from the middle of the sword where you cut the fuller? And what is it you used to treat the grip? Thank you in advance.

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Epic Workshopandrewv71

Reply 1 year ago

Please don't be shy.. ask away I love to help :) You can also contact me anytime on Instagram in private chat if you want.

For fuller I am using router plane, gouge chisel and scraper to smooth it. And also a sandpaper.

For grip I poured some linseed oil, mainly to get darker color and burning is for getting rid of this rope things and to darken it to look used :)

If you need any more help you know where you can find me :)

Cheers
~Moris~

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andrewv71Epic Workshop

Reply 1 year ago

Thanks man! I do not use instagram. I think I have it just do not use it lol. What brand router plane is that? I cannot find one on the website for my hardware dealer. Thanks again Moris!

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Epic Workshopandrewv71

Reply 1 year ago

Ah ok I just have so I can be in contact with my audience if they need any help :)
It is Veritas hand router plane :)

And when you make the sword be sure to send me some photos I would appreciate it :)

Have a nice day
~M~

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AF6YS

1 year ago

Echo the Excellent craftsmanship!

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ERICOSCAR

1 year ago

Dear author

Excellent craftmanship !

You should bring this to the annual medieval week on island of Gotland in Sweden.

But one thing makes me a little suprised.

On the handle you have carved in a christian symbol, crossing lines with a P.

Viking-age was a little before christianity had reached viking-land, when the German emperor provided the missionary Ansgar to christen the north, mainly the present Sweden, he immediatly came in to trouble with the viking pageants.

That would place your sword more in to medieval days when chrianity had a strong foot here.

Anyway a very nice piece of craftmanship !

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Epic WorkshopERICOSCAR

Reply 1 year ago

And yes I carved that symbol because of simple curiosity.
I saw it in one movie of which I don't remember the name :/

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Epic WorkshopERICOSCAR

Reply 1 year ago

Thank you for kind words :3
I think that travel to gotland is not possible unfortunately :/ I am from Croatia...

Finnaly somebody told me what that sign means because in video description I asked what is meaning of that symbol :)
But on other side of sword I carved rune Mannaz which I use like my makers mark which means to me a lot because Lord Of the Rings :D

Does that symbol has a name for it so I can research more about it or is it from some order.

Thank you one more time for nice comment :)

~Moris~

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XaviOrin

1 year ago

Awesome 'Ible! I am purchasing new wood working equipment and needed a project and this is definitely something I'm going to try out.