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How to Make a Sword Part 6 The Pommel and finishing it up!

This is the final part of the tutorial. We make the sword and put it all together.



Steel rod for pommel

About the Pommel - The picture here shows a disc of steel. The diameter is 2 inches. I have a rod of steel and I cut off this slice that is 3/4 of an inch thick. this is what I used for the pommel of this sword.

That can be a bit of a challenge if you don't have the tools to cut something like this. I have a friend who works in a machine shop and I asked him to cut this disc off the bar for me.

You do have the option of using something else like brass which is much easier to work with.

They don't sell this on the last I checked but you can get it at MSC or maybe Grainger. Same goes for the brass.


Fitting the pommel

The pommel goes onto the end of the tang. And it should match the size of the handle. This is something to think about when shaping or cutting it.

I used a belt sander to put a flat on it where it meets the handle.

Drilling the pommel

The pommel can be a little bit tricky. Because the tang is tapered. I drilled a series of holes each one smaller than the other and going down a little bit deeper than the previous one.

polishing the blade

OKAY! Almost time to assemble this handle together and finish the sword. But before we do that you should polish up the sword. Start at the 400 grit where we left off before and work your way to finer grits. You get as fine as you want to . depending on how polished you want the sword.


Now Let's Assemble the Sword

drill for pinning

Put the crossguard on the tang and fit it up nice and snug against the blade. Drill through both of them all the way through. I used a 1/8 inch drill to accommodate a 1/8 inch pin.


pinning the crossguard

This picture shows you the holes for the pin.



Cut yourself a steel pin that is a little bit long then pin it!

Once the pin is in place you can carefully trim it down flush with a file and emory paper.


pinning the pommel

Okay! Just about done. Now do the same process with the pommel. Put the handle on and drill through the pommel and tang. Then pin it!!


Your handle is complete and it looks great! You can now touch up the whole sword with some 1200 emory paper.


The Completed Sword

The sword - hand made



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