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Table of Contents
Decorative Sword/Machete for the Novice Metalworker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 2: Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 3: De-Rust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
http://www.instructables.com/id/Decorative-SwordMachete-for-the-Novice-Metalworker/
Author:Ikkalebob
The name "Ikkalebob" was invented by my cat when she ran across the keyboard.
http://www.instructables.com/id/Decorative-SwordMachete-for-the-Novice-Metalworker/
http://www.instructables.com/id/Decorative-SwordMachete-for-the-Novice-Metalworker/
Step 2: Cutting
Draw directly on to the steel the shape you want, and cut it out using an angle grinder with a metal cutting disc. Remember, you're handling a wheel spinning at over
10,000rpm while it's hurling near-molten steel at your face and its own power supply cable. It should go without saying that its important to stay aware of your
surroundings and to wear proper safety equipment (eye-protection, breathing mask, ear defenders and protective clothing including gloves). Also, don't make the mistake
of doing what I did and wearing anything nylon, it won't end well.
You could use a hacksaw, but given that the steel I used was 5mm thick you might be there a while. Next, you could either change to a grinding attachment or use a
bench grinder to perfect the shape, or if you're skilled enough with the angle grinder perhaps you don't need to do this part.
My angle grinder died at this stage and my bench grinder wasn't powerful enough, so I perfected the shape with a heavy duty file as pictured. Obviously this will take
longer, but since its a much slower and more controlled process there will be less clean-up to do later on.
http://www.instructables.com/id/Decorative-SwordMachete-for-the-Novice-Metalworker/
Image Notes
1. Shape to be perfected down to the bottom of the blue line.
Step 3: De-Rust
Using the angle grinder with a wire brush attachment, its easy to remove all the rust provided it's not too deep. Be warned though, the wire brush attachments can be
seriously painful to use. Whereas last time it was sparks flying at your face, now its needle-like pieces of wire. I was stupid and didn't wear gloves, and ended up with
bleeding hands. After that experience I always make sure that I am armed to the teeth before going anywhere near an angle grinder.
Some of the rust may be too deep to just use a wire brush, in this case it should just be fairly easy to grind off, but it all depends on the finish you want to go for. I wanted
an ultra reflective surface, so I had to remove all the rust. If you want a battered look then notice the second picture, the black speckles which were under the more
substantial rust could play to your advantage.
http://www.instructables.com/id/Decorative-SwordMachete-for-the-Novice-Metalworker/
http://www.instructables.com/id/Decorative-SwordMachete-for-the-Novice-Metalworker/
http://www.instructables.com/id/Decorative-SwordMachete-for-the-Novice-Metalworker/
http://www.instructables.com/id/Decorative-SwordMachete-for-the-Novice-Metalworker/
http://www.instructables.com/id/Decorative-SwordMachete-for-the-Novice-Metalworker/
Image Notes
1. Precisely why this is a bad idea.
http://www.instructables.com/id/Decorative-SwordMachete-for-the-Novice-Metalworker/
http://www.instructables.com/id/Decorative-SwordMachete-for-the-Novice-Metalworker/
http://www.instructables.com/id/Decorative-SwordMachete-for-the-Novice-Metalworker/
Image Notes
1. I thought these looked cool and was originally going to leave them in, but it was
too difficult to sand around them so they had to go.
Step 8: Handle
So this is the part where your hard work pays off and you get to spend a bit of time being a little more artistic and creative. I made an admittedly quite crude handle out of
some pine firewood I had lying around, and secured it using evo-stick and some electrical tape. I decided I wanted a leather wrap with a slight tropical sort of look.
I got out my big bag of 40 year old leather and looked for some pieces that suited the style I wanted to go with. I ended up going for a natural and rugged looking piece.
From there it was simply a case of cutting it into a thin strip and wrapping it around, securing it with panel pins at the ends. At first it looked quite ugly as the leather wasn't
snug against the handle, so to rectify this I cut the strip down the middle and wrapped it with two thinner strips rather than one thick one. I wrapped over the two ends with
some shoelace as a decorative touch and also as a way of feeling where the handle transitions into the blade so you don't cut yourself. I also found a ring and attached it
to the end as a pommel stone of sorts. The string more or less holds itself together but I used some evo-stick just to be sure.
Note that when designing your handle, you want an oval shape as a circular shape would make the sword very difficult to use, this is because in order to make a cut you
need to know exactly where the edge is pointing, and this is hard with a round handle.
http://www.instructables.com/id/Decorative-SwordMachete-for-the-Novice-Metalworker/
http://www.instructables.com/id/Decorative-SwordMachete-for-the-Novice-Metalworker/
Image Notes
1. Got dat Arnold jaw at least.
http://www.instructables.com/id/Decorative-SwordMachete-for-the-Novice-Metalworker/
http://www.instructables.com/id/Decorative-SwordMachete-for-the-Novice-Metalworker/
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jessyratfink says:
This is beautiful! great job :)
http://www.instructables.com/id/Decorative-SwordMachete-for-the-Novice-Metalworker/