Wooden medieval sword12/15/2023 (picture 4) This will probably take a while. Put the iron bar straight in the vise ( picture 3 ) and take the square file and file from the one hole to the other. ( the dimensions are on picture 1) Put the piece in the vise and drill 2 holes in the iron bar. Now draw the square hole in the middle on the iron bar. Take the hacksaw and cut of a piece from the iron bar, with a length of 190 mm. Step 1: Make the square hole in the guard flap disc grit 80-120-220 ( for small angle grinder) Round off the eges of the handle (picture 14) excepted the 20mm where the guard is going to slide over. (picture 12) Now grind the slanted side on the topside and make sure that the fuller and the 2 slanted sides are all in one line to the point. Now it's time to shape the point, begin at the end of the fuller and grind it towards a point. You can just change the disk pad and the shape stays the same. The advantage of using this machine is that you don´t have to worry that the disk changes shape after long time use. Do the same with the disk pad grit 120 and 320. Take the small angle grinder and the disk pad holder with a 80 grit disk to level the cutting edge.(picture 10) If you move the grinder from left to right like picture 11 all the smaller bumps and dents will come flattend. (picture 4-5-6) Don´t form the point yet because you will have no space to clamp the blade down. Take the large angle grinder with the metal grinding wheel and begin to grind the slanted side of the cutting edge. This will make it easier to grind it in one smooth movment. Now take the 2 clamps and the sword and clip it on the work table, make sure that half of the blade is outside the work table. Make sure that the line of the cut is straight or this will present problems in the future when you grind the cutting edge. Take your small angle grinder with the 0,8 cutting wheel and cut out the shape of the blade. Step 3: Cutting out the shape of the blade On the topside it decreases over a length of 30mm. On the side of the handle the mill should gradually decrease from 0 to 4mm in depth over a length of 15mm. It should start 40mm above the handle, finish 50mm for the top and is 4mm deep. Put the bar in the vise on the milling machine and mill the fuller in the bar. Now you know where the blade begins and ends. The dimentions of the blade are 800mm long, 40mm wide. I did not have the right size, so I had to cut the shape out off the bar i had. The knife itself is 40mm wide, if you have an iron bar with the correct dimensions you will have to grind less. Step1: Drawing the shape of the blade on iron bar metal grinding wheel (for large angle grinder) cutting wheel 0,8 (for small angle grinder) disc pad grit 80-120-320 ( for small angle grinder) disc pad holder ( for small angle grinder) flap disc grit 120 ( for small angle grinder)
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