Shaping the blade Rough out design Sketch on blank Cut off extra material Grind Rough out shape Thin desired sections Start to form the blade File Smooth ground sections/ define blade structure
Quenching Need to add hardness Use blow torch to heat blade Quench in water Alternate: Wrap blade in clay except for sharp edge, then place in kiln at ~2000 deg F and quench http://evergreen-rentals.com/index.php?main_page=index&cPath=2_40
Form Handle Create “pommel” or finger guard Create shoulder at end to prevent hand from slipping Will later cover in wood and rivet or epoxy in place
Conclusion Absolutely have to use hard metal such as high carbon steel, stainless steel, titanium alloy, etc. Must anneal high carbon steel Form steel to desired shape Harden blade for long lasting sharpness
Acknowledgment Many thanks to my sister Ruth and her boss for letting us use the Kiln, also to my Dad and brother for the files and tips for grinding.