The maker faced the challenge of shaping the high-carbon steel strip into a finished blade using only a press and a hammer on an anvil. This process required careful preparation of the 1095 steel strip before it was heated in the gas forge. The resulting sword features a long, matte-black blade that possesses a straight spine and an angled point. The hilt components present a striking appearance, utilizing metal stock that features multiple rectangular cutout slots and a straight metal handle, which were created by cutting, heating with a torch, bending, and welding.
Assembly of the hilt required several steps, involving rotary grinding tools, belt sanders, and sandpaper to refine the components. The blade underwent significant work, being ground on a belt sander before it was reheated and quenched in an oil trough. For a refined finish, the maker applied a chemical bluing liquid to the blade flats using a cotton pad. This deliberate choice added a layer of detail to the overall presentation.
Testing showed the fabricated sword successfully cut through several items, including a butternut squash, milk cartons, and a plastic beverage bottle. While the sword performs impressively, the maker mentioned that the current setup is not fully optimized, noting an interest in upgrading to a real hydraulic press to facilitate future projects.
Project by Hammer Scale. Watch it on their YouTube channel: