Forging a Damascus Spartan Sword

hey folks welcome to the channel in today's build  we're going to build a sword not just any sword   but the sword from the movie 300 this will be  my take on the sword so it won't be historically   accurate but we're gonna have some fun and  this one we're gonna make out of damascus   please folks remember to like and subscribe  it helps me a lot let's check out this build do do so okay i got this forged out into a long bar now  now i'm going to use this cool tool because   equal measurement i want four two three four so  it's pretty cool i can just do this there we go okay i'm just gonna lock this and then mark  that on my band saw and we're good to go   here we are cut and re-stacked for a total  of 108 layers i'm going to leave it at that   back in the kerosene and back in the forge so so i'm done with the initial  forging with the press i got a basic   shape and now let's go to the anvil  and hammer it out a little more okay i'm done the forging on this blade uh now  i'm gonna draw it out uh on top of the steel   and we'll start the grinding what so so i've done a bunch of the layouts  i'm just going to do the center line okay i got my guidelines we can start to grind okay i'm ready to put the fullers in this  blade i've decided to use a ball end mill   and do it on the mill so here it is after initial grind i've taken  a file done the file work on this transition   this is a much different steeper angle than this  part so this had to be hand filed as you saw   and i'll work on that transition   with sandpaper as well and you can see i got  quite a bit left to take after the heat treat   i've also put the fullers in um turned out  pretty good i gotta take some of these bumps   out but i'll do that with sandpaper the one issue  i didn't take account for is i did want the um   the uh fake edge here the false edge to come down  so i'm gonna have to put it up a little bit higher   than i wanted um just because i got that fuller  there so it'll be close but i'll make it work   so folks all of this and about four hours  of time is what it took me to sand out the   fullers on this um because this thing is so large  um i couldn't really clamp it well in the vise so   i was getting a lot of chatter which meant a  lot of little grooves that i had to sand out   and i wanted to do that for the heat treat because  it would have just taken twice as long after so   much better now and i'm gonna do a little bit  more grinding just to take some meat out of this   and uh and then after the quench so i'm ready to mill the shoulders on the  sword here i've got it locked up in the vise   i've put a filing guide on here butted up against  the edge of the vise and this way i've locked this   on i've zeroed the uh the mill so i know what the  cutter is going to be i'm going to cut both sides   okay and then leaving this on lets me flip it  over i know it's exactly against the vice and i   can mill the other side and it should be precise  so this way i get perfect shoulders on the sword so so it took a while but i cut the top and  bottom guards out of this one inch piece of um   a bar stock that i had i just figured  it would be easier than try to   forge it and bend it so i just cut them  out and now we're ready to grind them to shape so i've done some initial work with  the small wheel attachments but   doing these separately it's really hard  to get the same level so i've put these   together flush them up and i'm just going  to do it by hand to do the finishing looks like we're close enough uh and now i'm  gonna go to the mill and just mill these two faces   to be the same probably these two as well i've got the guard ground to shape um   of what i want now i've just marked off i want a  little taper here so i've marked off with calipers   and i'm just going to grind down so we  have a nice taper here so let's do that so we're going to finish this  off on this um 2x72 buffing belt   um i've never actually used it before  but we're going to check it out so all right i'm ready to wire wrap this handle you  see i shaped it a little bit i put a little um   black uh leather die on it  just in case you see a bit   through it i just wanted it back to be  black you can see i've drilled some holes   for the starting of the wire  and then there's little notches okay and it's going to go in this  contraption which i'm going to be able to   turn and it only goes one way and here's the  wire so first thing i'm going to do is twist   this wire okay folks i'm ready to twist this  wire i've got it uh tied into a drill here   and way down there in the garage i've got  it attached to another piece so here goes well i managed to get the wire all twisted i've  got it wrapped around a bucket over there just   so it doesn't get kinked i didn't realize it was  gonna want to have a tendency to unravel i don't   know why that surprised me um i've got the handle  set up in the jig i'm gonna put the first um   set the wire in there seat it with a  toothpick and then we should be ready to go so no no no so i'm putting contact cement  around here for the wire to stick to and then it should be a matter  of just pushing it in place okay time to etch my maker's mark uh this  time i'm actually going to put it in the guard   so i've got this hooked up to a  battery charger which i'll plug in set at 10 amps which is the medium setting on  this one i got a saltwater solution i've got the   positive hook to the um to the guard don't  switch those because it doesn't work if you   connect to the negative to the guard or to  the the piece you got to get this pretty wet soaking it especially since it's  you want it touching the electrode   and then this is important dab off all  of the excess so it's just damp and then just dab it over and just keep going over it so what i do is i take one of these  marking pens and i just kind of   feel the edge and you should feel a little  like a little ridge there and if you do   then you're usually pretty good it's deep enough  other option is to just take the tape off one side   and just peel it up just so that in case you  have to put it back down you'll get it in the   same place yeah that one came out really  nice okay i've got my maker's mark in the   guard i'm going to use some of this cold bluing  solution because i want the fittings to be dark   and not shiny so i'm gonna try this out i've  never used it before so we'll see how it goes so you

Channel: Tyrell Knifeworks

Views: 220,597

Rating: 4.886034 out of 5

Keywords: Forging a Damascus Spartan Sword, Forging a Spartan Sword from the Movie 300, forging a spartan sword, spartan sword, making a spartan sword, building a spartan sword, sword from the movie 300, sword from 300, forging damascus, damascus spartan sword, forging a 300 sword, spartan sword making, damascus sword making, damascus sword, forging, sword making, knife making, tyrell knifeworks, tyrell, 300 movie, greek sword, King leonidas

Id: xeXSS5uCiyk

Length: 23min 19sec (1399 seconds)

Published: Sun Jun 13 2021