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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.

 

THE POMMEL

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 amazon.com 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.

 

pinning

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

 

 

The Complete Bladesmith

The Complete Bladesmith: Forging Your Way To Perfection

Looking for instructions in bladesmithing that'll put you on the cutting edge of the custom blade market? Then this definitive guide to forging world-class blades is for you. Written by a master bladesmith, this book tells you how to set up your forge, select your materials, fashion grips and hilts, grind edges and much more!

 

 

Techniques Of Medieval Armour Reproduction: The 14th Century (Medieval & Renaissance)

Few historical icons can match the evocative power of the medieval suit of armour, and this epic new book is a complete course in the tools and techniques of the modern armourer's art. Through more than 1,000 detailed photos and clear instruction, Brian Price presents a working handbook for aspiring and active armourers who want to develop their skills in the production of medieval armour in the style of the 14th century. The book is divided into four sections: a sweeping history of armour and its production from its medieval roots to its modern revival; a practical introduction to all the tools and supplies necessary to equip a modern workshop; a thorough review of key techniques; and a series of actual courses in constructing armoured defenses for the head, body, arm, hand and leg. Taking the reader through the construction of an authentic medieval harness from conception to completion, Techniques of Medieval Armour Reproduction is a vital addition to the libraries of serious craftsmen, historians, collectors and researchers.

 

 

 


 

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