War Sword
Many fans of medieval times love to collect swords and knifes. They often search out custom-made war swords at renaissance fairs. These swords typically start at a couple hundred dollars, and the sword goes up in price with customization. While it may be easy to purchase a war sword, making one yourself is much more fun, and has the added value of being a craft of your own.
Instructions
Heating the Steel
1. Build a fire in a fire pit or charcoal grill. Place enough wood or charcoal that it fills the pit a little more than halfway up. Allow the fire to burn until the coal or wood is red hot.
2. Insert the steel bar deep into the coal or wood. It should be completely buried. Use a tool to push it in if needed.
3. Allow the steel to remain in the fire until it has gone out. Let the steel cool on it's own. Do not remove it until the ash has completely cooled down.
4. Remove the softened steel from the pit. Use a pencil to mark the shape of your sword. Do not forget to draw the handle.
5. Use a bandsaw to cut the outline of the sword. If you do not have a bandsaw, you may use a hacksaw. File down any rough edges.
6. Use the file to shape the sword to the desired sharpness. Be sure to make the sword double-edged. You can use a grinding wheel, or rough and smooth files. Finish the blade with wet and dry paper.
Tempering
7. Heat the blade again using the fire pit. This time leave a portion of the handle sticking out. This will allow you to see when it has turned red.
8. Use a pair of pliers to remove the sword. Plunge it immediately after, into a bowl of warm water. Be sure that the water isn't too cold or too hot.
9. Allow the blade to cool. Remove it from the water. Clean the blade with wet and dry paper.
10. Heat the blade once more, again leaving a bit of the handle sticking out. Once it has turned dull red, remove it. Once again with the point down, plunge it into the water. Move it up and down as it cools.
11. Clean the blade again with the wet and dry paper. Heat the blade once more, leave part of the blade sticking out. The blade will begin to change color. It will turn a bright yellow, and then medium yellow. Do not allow it to change past the medium straw/yellow color. The next color would be blue. As soon as it turns the medium color, remove it and plunge it into water once more. Allow the blade to cool.
Handle
12. Lay one wooden block flat. Trace the tang (section of metal sword forming the handle) on the flat side of the wooden block. Repeat the process with the second wood block. Chisel out the indentation for the tang. This is the area between the lines traced for the tang. It should be chiseled to about half the width of the handle. The tang will be inserted between these two indentations when complete. When finished the two pieces of wood will lay flat around the inserted tang.
13. Roughen the indentation in the wooden blocks (the area where the tang will sit) with sandpaper. Place epoxy all over the inside of the handle, and where the wood will come together when placed around the tang. Be careful not to get it on the outside.
14. Insert the tang between the wooden blocks, and clamp the pieces together. Use an even pressure to make sure the glue spreads evenly. Allow the wood to remained clamped for approximately 4 days.
15. Trace the desired handle shape on the wood. Use a wood carving knife, and the files to shape the wood. When you are finished decorate with a wood burning kit.
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