Forging a SWORD out of Rusted Iron CHAIN

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Well, This Sword took me too long to make and this was not easy to make it such perfect. This is the longest sword i have ever made and this sword was one of the hardest project i ever done. And only the forging process took me about or more than a week.

Overall Sword Length : 45 Inches
Handle Length : 10 Inches
Blade Length : 35 Inches

All the Processes are below of making this beautiful SWORD:
It took me almost a week to hand forge an Iron Chain piece into a long Metal Strip and this was one of my hardest forging ever. I don’t have a power hammer so i did all the forging with hands and turned a chain piece into an almost 45 – 49 inches long sword.
I started some rough grindings of long forged strip on my Belt sander and turned the strip into a long Sword shaped steel piece. I also hand sanded the sword with the help of file to remove almost all the roughness of the sword.
o. I made the Fuller with the help of angle grinder and rotary grinder.
o. The blade bevel was made by my professional angle grinder and belt sander.
o. Hand Sanded the blade to remove roughness.
There is a professional way to hard a sword on coal and Tempering the blade is the best way to increase the Strength, Hardness and Toughness of the sword.

WAX Casting:
I made the Guard and Pommel of the sword with the help of wax. And this took me alot of time to make perfect molds of wax. After the molds were done i poured some casting plaster on the wax and melted the wax inside the plaster with the help of my own made furnace.
The Handle contains three parts.
o. GUARD: I made the guard by casting brass, and filled some area of guard with black Epoxy resin.
o. Pommel: I beautifully made the pommel by casting and the main purpose of pommel is not let the hand slip through the handle.
o. Wood: A nice piece of wood used as the handle and i stripped an artificial leather on the wood with the help of adhesives and embedded our RH logo onto the wooden handle.

Forging a SWORD out of Rusted Iron CHAIN

Always wear leather gloves while sanding knives. Always keep a First Aid Kit at your work place.

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Random Hands