DIY sword made from 5 materials with step-by-step manufacturing instructions

Nikolay Chebotarev, Inna Drabkina - especially for the Ludota website

Today our interlocutor is an artist and blacksmith from America, David DelaGardelle. He has many excellent swords, knives, axes, and has also worked with a Hollywood film studio.

Good afternoon, David! Tell readers from Russia about yourself. Where were you born and where do you live?

Greetings! I was born in Waterloo, Iowa in November 1988 and in 1995 moved my family to Muncie, Indiana where I now work and live with my fiancée Hannah. As a child, I always spent my summers on the Door Peninsula (Door County, Wisconsin) with my German grandparents, and I still go there for the summer.

Who did you study for and how did you use the knowledge you gained in your work?

I was planning to study art and metalwork at Ball State University in Muncie, Indiana, but had not even finished my first semester when Marvel Studios signed me to a contract to make swords for the movie Thor. This contract gave me the opportunity to realize my dream of leaving school and becoming a professional gunsmith and entrepreneur.

The final chords in making a sword

Do you have any interesting family legend about your Norwegian and German ancestors? How far back does it go?

Good question! My German grandfather told me a couple of years ago that his grandfather was a knife sharpener and polisher, as well as a skilled leather worker. I like to think that these skills and abilities are in my family, inherited from my ancestors, and I hope that I will pass them on.

Creative atmosphere

Where do you find inspiration?

I was lucky that I grew up in a family where any creative endeavors were always supported. I appreciate this support and am grateful for the rich imaginative environment my family has created.

David's drawing

I immersed myself in everything that came from the pen of Tolkien and his friend Clive Staples Lewis. Both of these writers had a huge influence on me when I was little, and continue to shape me as a person today.

I loved books like John Bunyan's Pilgrim's Progress; these are books about how people fight for what they believe in and how they become real people in a hostile, crumbling world.

I was just binging on book series like Redwall by James Brian Jakes, full of joy, laughter and adventure. I loved the classic medieval chivalric romances and the Arthurian cycle, ancient Celtic myths and fairy tales. I also loved pastiches like “The Ballad of the White Horse” by Gilbert Keith Chesterton.

I was especially shocked when I first heard Beowulf in Old English. Since then, I have been eager to penetrate into the past, into that reality, to understand what the ancient legends are talking about, and to know the truths contained in them.

In the workshop yard

That’s how, thanks to the creative atmosphere that reigned in the family, and among ancient stories and legends, I began to gradually master the basics of weapon craftsmanship. I came across the arms business at the sites of historical and cultural centers of living history and began to look for information on the Internet.

I immediately began purchasing the basic tools needed and began making my dream a reality.

David carves a pommel for a Carolingian sword.

I really like to create unique, unparalleled battle swords using as traditional technologies as possible. I am trying to forge symbolic swords that could tell the story of beauty, justice, honor, strength, weakness, depravity of human nature and the integrity that can be found through redemption.

Do you fence with swords yourself?

I am not a swordsman, nor do I know any traditional sword fighting styles, but I do know how to make a good sword suitable for combat. I respect and admire everyone who teaches how to wield real historical swords! I think it’s simply amazing the movement of people reviving the ancient traditions of fencing with swords in the modern world.

Who are you more of a gunsmith, an artist or a designer?

Honestly, I believe that I am learning to be both a gunsmith, an artist, and a designer.

Decorating the scabbard is an important part of the process.

I think these three professions are closely related, especially if you practice an ancient craft (like gunsmithing) today.

Far East

1. Tao. Sword of the Kachin tribe, Assam. The example shown shows the most common blade shape of many known in this region.
2. Dao (noklang). Two-handed sword, Khasi people, Assam. The hilt of the sword is iron, the trim is made of brass.
3. Dha. Single-edged sword, Myanmar. The cylindrical hilt of the sword is covered with white metal. Blade inlay with silver and copper.
4. Castanet. The sword has a carved wooden hilt and a steel safety guard. Decorated with silver and brass inlay. Sri Lanka.
5. Single-edged Chinese iron sword. The handle is a blade stalk wrapped in cord.
6. Talibon. Short sword of Filipino Christians. The hilt of the sword is made of wood and braided with reed.
7. Barong. Short sword of the Moro people, Philippines.
8. Mandau (parang ihlang). Sword of the Dayak headhunter tribe, Kalimantan.
9. Parang pandit (pandat). Sword of the Sea Dayak tribe, Southeast Asia. The sword has a single-edged, forward-curved blade.
10. Kampilan. Single-edged sword of the Moro and Sea Dayak tribes. The handle is made of wood and decorated with carvings.
11. Klewang. Sword from Sula Vesi Island, Indonesia. The sword has a single-edged blade. The handle is made of wood and decorated with carvings.

Sword as a symbol

What is a sword to you? Just weapons or something more?

For some, a sword is just a sword. But for those who are able to understand me and my aspirations, I will say that it is necessary to have the same inclinations, the same adventurous streak, to appreciate my sword when you hold it in your hands.

I hope that you can feel the desire to live not with violence, hatred and revenge, but the desire to love other people, to live with honor, respect, high moral ideals.

I firmly believe in the concept of “meta-statement”, absolute unchanging Truth, the existence of good and evil, and that in the broken human heart seeking redemption, wholeness, good and evil are opposed to each other.

New blade. It should be perfectly smooth.

I think the sword is an ideal symbol to express these truths; the sword also provides insight into what makes a person human.

And I really hope that through my work I can inspire other people to use the talents God has given them for good, for the sake of something good and good.

Your swords, even if they are made based on weapons from the Renaissance, bear a strong imprint of the Early Middle Ages. For example, the Carolingian sword “Osbert” has a rather late, long guard, and the two-handed sword “MiekkaOkaat” is decorated in the style of the Early Middle Ages - a difference of five centuries. What influenced this design decision?

This is because I want it so much, and because, fortunately, I have the ability and opportunity to do it! I love what I do and don't want to limit myself creatively.

I really enjoy forging historically accurate swords, but I also enjoy exploring the strange worlds of my imagination inspired by the homes and landscapes in which I grew up.

There is no law that requires gunsmiths to forge exclusively historically accurate swords. Why not make a sword that has never existed before?

I find a special charm in creating original creations that no one has ever seen before.

Hardening steel in the Middle Ages: from copper to iron

Initially, the metal for making swords and knives was copper. This is a fairly soft metal: it does not hold the shape and sharpness of the blade well. Therefore, copper was soon replaced by a more durable alloy of copper and tin - bronze. But even such weapons were imperfect, and also expensive. Therefore, blacksmiths looked for new solutions.

They learned to process iron later. Why? Firstly, copper and bronze lend themselves well to cold forging, but iron had to be forged in a hot state. Secondly, where to get raw materials? In Japan, for example, the Iron Age began only in the 7th century AD: the earth was poor in metals. In Europe - much earlier. Even before our era, iron ore deposits were found here. Iron was first used to make weapons in Asia in the 12th century BC.

Sword forging - quality priority

How is a new sword born? What stages does forging a sword include, starting with an idea?

The process of creating a sword always begins with an idea, with a spark of inspiration, and only then the sword takes on flesh and blood.

I start by creating a sketch on paper or in Photoshop for digital rendering - it all depends on the complexity of the idea.

Once I decide on a design, I start working with metal.

If the blade is being made using pattern welding, I weld strips of metal made from rods into a blade base block. If the blade is made from one strip, from one metal, I choose a piece of high carbon steel according to the size of the blade.

Then I trim, process and forge, giving the blade the desired shape. I make the bevels by grinding the blade on a belt sander.

When the shape of the blade is almost as desired, I begin heat treatment. I harden the blade by heating it above its decalescence temperature (to a bright red or dull orange color) and then immerse it in oil.

After hardening the blade, I release it to give it flexibility and elasticity so that it does not break.

Then I start working on the handle.

You can make a handle using steel, iron, bronze, copper, wood, horn and leather. The handle is carefully held together to prevent it from falling apart, and then the sheath is made from similar or complementary materials.

I take the final finishing stages of each sword very seriously, as every detail is important to me. The choice of color, material, polish and patina says a lot about the meaning behind the sword and what the sword symbolizes.

What is the most difficult thing for you when creating a sword?

I think the hardest thing for most gunsmiths is finding the balance between design beauty and functionality.

I believe that any professional gunsmith will agree that you need to start from historically correct and time-tested functionality and quality. And on this basis, fantasize and express yourself as an artist, with the help of jewelry and aesthetic design.

Single-edged sword of the Norwegian Vikings as interpreted by David. We had a whole article about this weapon - to read it, click on the photo.

But you cannot sacrifice quality and functionality for the sake of design. Both appearance and functionality are important in their own way, but priority must still be given to quality.

Are the patterns on the blade damascus?

Yes, that's him. I forge my own blades, my patterned Damascus, in my workshop unless I am using steel made by another smith. I typically use 1075 high carbon steel and L6 tool steel. It is very difficult to control the resulting pattern; for the most part it happens on its own.

In the photo there is a so-called “package” of several metal plates of different types. They are selected depending on the carbon content of the metal. David's task is to fuse them together through certain forging operations. Then from the resulting piece of metal it will be possible to forge a sword, knife or ax. This method is called welding damascus forging. You can recognize this method of forging thanks to the characteristic pattern that will appear on the surface of the blade due to the uneven distribution of carbon - after all, the metal, although it will be uniform, will remain heterogeneous.

Does forging a sword end with sharpening it? And if so, do you somehow register them with the police? Or is it possible to sell swords in the USA without documents for them?

I make 100% functional real swords so they are of course as sharp as real historical swords, but I am not legally prevented from selling my swords in America and I also sell them to many other countries.

The blade has not yet turned into a sword, but is already thirsty for blood

Types of swords and their characteristics

In the past, the sword had special significance. There were specimens, like works of art, that were considered family treasures. In battle, they used products that were more modest, but no less noble and strong.

The design of the sword itself is quite simple: a long blade with a hilt. However, the products come in various forms. The main purpose of the sword is to cut and thrust.

The most common and easiest to manufacture are straight and one-and-a-half blades.

One and a half blade

And the longest and heaviest is two-handed, it delivers heavy and fatal blows.

Two-handed sword

Based on their shape, blades are classified into three types. Each of them has its own advantage in battle:

It should be understood that different blade shapes can be used to produce different strikes; you should not stop at one type. The ability to use various swords distinguishes a real warrior from an amateur.

Balancing and center of gravity of the blade

Sometimes a seemingly perfect sword may turn out to be inconvenient for its owner. It all depends on the correct balancing of the product and the anatomical features of the person. Correct placement of the center of gravity is the key to success in battle.

The most popular is its location on the blade , just 10-15 cm below the guard.

With a shifted center of gravity closer to the tip , the blow of the blade gains greater force, but controlling the sword becomes more difficult.

When the balance is shifted towards the handle , it may seem that controlling the product has become easier. But the force of the blow and its accuracy will decrease.

Correct balancing of the sword

Optimal sword sizes

To make a sword with your own hands, you will need to find out what size it will be:

• if the plan is to make a two-handed blade, then you should take a stick and measure the distance from the ground to the chin, this will be the total length of the product;
• a weapon in the Slavic spirit should reach the warrior’s sole in a lowered hand.

With such simple techniques you can get a blade that is convenient for the owner. But it is difficult to forge swords for an entire army, selecting individual sizes for each warrior. That's why there used to be certain standards.

What kind of swords were made?

Short swords were made 600-700 mm, and long swords were made a little more than 800 mm.

What was the weight of the sword?

The weight of the products varied from 1.5 to 5 kg.

What were the parameters of medieval swords?

Medieval swords were made more than 900 mm in length, but their weight was not significant, about 1.3 kg.

Today, modern fencing masters recommend the most suitable sizes for the product:

• the full length of the sword is the distance from the floor to the swordsman's chest;
• handle length 2.5 palms;
• the length of the guard is 1.5 palms;
• center of gravity 5 fingers along the blade from the guard.

Knowing the parameters of a swordsman, it is not difficult to make a weapon as convenient as possible. There are still some details left to figure out and you can safely start making a sword with your own hands.

Materials for making a sword

Craftsmen have a variety of raw materials at hand to make swords. The main task is to know for what purpose the weapon is being manufactured.

Pen and Photoshop

Where does your passion for drawing come from? How did you develop your abilities?

I have always liked to draw, since childhood, and I always dreamed of becoming an artist. So you can say that the urge to draw is in my blood. Most of my relatives are involved in art and are creative professionally.

David's illustration for Tolkien's Farmer Giles of Ham

What books would you like to illustrate and why? How would you draw your favorite literary characters? Why exactly like this?

I'd really like to illustrate some of Tolkien's lesser known works like Farmer Giles of Ham or The Blacksmith of Great Wootton. And Beowulf and the poem Sir Gawain and the Green Knight. Probably almost any work of classical literature or myths. However, I'm not a huge fan of most modern fantasy.

Do you come up with the designs that are crowded on the sheath yourself or do you repeat ones you saw somewhere?

I design my own jewelry and also draw on historical motifs and designs. I try to bring my ideas and insights into every piece I create.

Africa and Middle East

In most of these regions the sword is a very common weapon, but in Africa it is rare and difficult to date. Most of the swords shown here ended up in Western museums and collectors thanks to travelers in the 19th and early 20th centuries.

Africa

1. Double-edged sword, Gabon, West Africa. The thin blade is made of steel, the handle of the sword is wrapped in brass and copper wire.
2. Takouba, sword of the Tuareg tribe of the Sahara.
3. Flissa, sword of the Kabyle tribe, Morocco. Single-edged blade, decorated with engraving and inlaid with brass.
4. Cascara, a straight, double-edged sword of the Bagirmi people, Sahara. The style of this sword is close to Sudanese swords.
5. The double-edged sword of the East African Maasai. The blade has a rhombic cross-section; there is no guard.
6. Shotel, double-edged sword with a double curved blade, Ethiopia. The crescent shape of the sword is designed to strike an enemy behind his shield.
7. Sudanese sword with a characteristic straight, double-edged blade and cross-shaped guard.
8. Arab sword, XVIII century. The blade is probably of European origin. The silver hilt of the sword is covered with gold.
9. Arabic sword, Longola, Sudan. The double-edged steel blade is decorated with geometric patterns and the image of a crocodile. The hilt of the sword is made of ebony and ivory.

Near East

1. Kilic (klych), Türkiye. The example shown in the figure has a 15th-century blade and an 18th-century hilt. Often, at the top, the kilij blade has an elman - an expanded part with a straight blade.
2. Scimitar, classic form, Türkiye. A sword with a single-edged blade curved forward. The bone handle has a large pommel and there is no guard.
3. Scimitar with a silver handle. The blade is decorated with corals. Türkiye.
4. Saif, a curved saber with a distinctive pommel. It is found wherever the Arabs lived.
5. Checker, Caucasus. Circassian origin, widely used by Russian cavalry. the blade of this specimen is dated 1819, Persia.
6. Dagger, Caucasus. The dagger could reach the size of a short sword; one such example is presented here.
7. Shamshir, typical form. Persian saber with a curved blade and a characteristic hilt.
8. Shamshir with a wavy blade, Persia. The steel handle is decorated with gold inlay.
9. 18. Quaddara. Large dagger. The handle is made of horn. The blade is decorated with etching and gold checkering.

Forging a sword for cinema

How did the creators of the movie Thor contact you? What task was assigned to you?

Working on Thor was definitely a great opportunity and incredible luck for me as an artist-entrepreneur. This film project gave me the opportunity to “set out on the road with faith” and devote myself entirely to the craft of a blacksmith-gunsmith and become an entrepreneur.

He also helped the business grow larger than it would have otherwise. But this is far from the most rewarding project I've worked on.

I am much happier when I work with ordinary people and help them make their dreams come true. I love building strong relationships with clients and exceeding their expectations by making swords even better than they dared to dream. This is what gives me the most joy in my craft.

The team of prop makers who worked on this film came to us with rough concept sketches, which were completed by one of them, a talented artist.

Then I, along with the team, began to hone these ideas in Photoshop to make the weapon as functional and realistic as possible.

While working on the design, we did everything we could to, within the given parameters, add historical details that can be seen on some swords of the ancient Germans, for example, sword fullers or knotted ornaments.

David puts a pattern on the guard of Heimdall's sword

However, the sword itself had to be majestic and literally “otherworldly”.

And besides the actual steel swords that the heroes were armed with, we made two aluminum copies of them, especially for the stuntmen who fought on camera.

Workpiece pulling phase

The next phase was very long, tedious and labor-intensive - drawing out the workpiece. Usually this was done by several masters or students - apprentices of the blacksmith. Under the powerful heavy blows of the forge hammers, the workpiece acquired the outlines and shapes of the future blade of a knight's sword. At this moment the shank and the fuller were forged. Also, there was a simpler option for making a fuller, when the blade part was turned on a cooled blade, however, with this technique the structure of the steel was damaged, so this option was relevant when creating something second-rate, and famous blacksmiths did not use such a technique. By the way, it was in this way that the fuller was forged (carved) on the fake swords of Ulfbert.

When the steel was drawn out and the workpiece took the shape of the future blade, the blacksmith carried out fine forging, after which the density of the material increased, and the shape took on a more complete appearance. This process occurred when heated red-hot. If minor errors were discovered during the fine forging, they were easily corrected with a file.

Important project

Tell us about The Narrow Road project. What kind of film is this and what is its plot? Who's starring in it, who's directing it, and where can I watch it?

The Narrow Road is an ambitious film project currently in production. I have been collaborating with the project for the last 2 years. We are still in pre-production, so the film's release date is not yet known.

I work on the project as the lead artist, gunsmith, consultant and gunsmith technician, and graphic web designer.

The film is based on John Bunyan's classic book Pilgrim's Progress. This book was first published in 1678 (it greatly influenced authors such as Tolkien, Lewis, and Chesterton) and is considered the greatest allegorical work of all time.

The novel is considered an English classic, and for many generations it has sold millions of copies around the world and has been translated into dozens of languages. This epic work describes a pilgrim's journey in search of salvation from impending doom.

Christian, the main character of the book, a pilgrim, must overcome many obstacles on his way and meet a variety of characters - strange, unbridled and even evil - on the way to the beautiful Heavenly City.

This book is a wonderful allegory of the life of a believer, the struggle against sins, and salvation in God, who alone can give us deliverance from sins and suffering. She presents deep questions of theology in simple, accessible, yet powerful language. Readers who loved the book for its ideological message, simplicity and interesting adventures, I think, will accept and love this film, which follows the letter and spirit of Bunyan's novel.

Filming of “The Narrow Road” is underway

The film will use modern cinematography technology to set the action in a dream-like world like Bunyan's, and the art direction, while fantastical, will resemble a medieval world.

Metallurgy in Japanese

Iron came to Japan later, but despite this, Japanese swords are known for their deadly characteristics. The “master of swords” in Japan in class society was on the same level as the samurai. His skill gave him this right.

Blacksmiths-gunsmiths - kaji, were outside the rank of artisans and were part of 80...120 blacksmith schools, their number changed at different times.

Iron ore was mined from river sand; smelting steel from such ore was a labor-intensive and time-consuming process. After smelting, the resulting steel was forged many times until a homogeneous dense mass was obtained. Strips of such material were combined by forge welding into a package and forged again.

It is necessary to distinguish the Japanese technology for producing a composite from layers of metal from the European technology for producing Damascus steel. If in Japan it was customary to weld layers of steel onto the base, then in the manufacture of Damascus a monolithic package was used, united by forge welding.

Making Japanese swords was a complex process. There were two main types of sword forging:

• itame - a repeatedly folded package of high-hard metal was welded onto a steel strip of mild steel, which formed the blade;
• masame - also a strip of soft steel was used as a base, but a rolled strip of hard metal was forge welded onto the blade area and a blade made of hagane - a very hard alloy - was welded onto it.

The blade itself had a wedge shape, which simplified its processing and repeated welding.

The production of a samurai sword differed in technology and quality from the products of European masters. Although it had some common features.

The simple philosophy of a blacksmith

What do you want most in life right now?

My goal now is to live a simple, humble life, praising the Lord, giving thanks to him for blessing me and giving me life, breath and the opportunity to do what I love. Serving my family, loving my fiancée, and creating works of art with my own hands.

I hope to make many more swords in the future; these swords ripen in me like grains in the ground. I have many more stories and ideas to share through steel, iron, wood and leather, and I hope that my work will inspire and delight people who hold or view my swords.

I hope that my swords will tell the story that one must live for the sake of justice, purity, sacrificial love for others, and not for the sake of profit and selfishness.

A sword can become a symbol of evil, but it can also become a symbol of good; with it you can lay down your life for your friends, just as our Savior laid down his life for us.

Making a sword with your own hands from various materials

Naturally, the most popular are swords made of metal and wood. But we should not forget that in nature there are many materials from which you can make a sword with your own hands. And with skillful finishing, no one will be able to distinguish it from the real thing. Let's consider several options.

Plywood sword

A wooden sword may be too heavy for a child, but one made from plywood will be just right. Making a blade from plywood is not so labor-intensive, but it has its own small nuances. The following materials will be required:

• plywood itself, 5 mm thick;
• PVA glue or superglue;
• any waterproof paint;
• tape or strong thread for wrapping the handle;
• jigsaw, hacksaw, file and sandpaper.

Take the time to make a template on cardboard and mark the slopes. Do not forget that for the strength of the product, you must try to keep the thickness of the handle and the middle of the blade to the original thickness. There are not many manufacturing steps, proceed like this:

1. Transfer the sketch onto the plywood.
2. Then use a jigsaw to carefully cut out the outline.
3. Next, use a file to gradually remove the wood along the slope lines.
4. Make a crosshair and pommel.
5. The parts should fit tightly to each other; install them in their places, having first thoroughly coated them with PVA glue.
6. After drying, we begin to sand the entire product with sandpaper.
7. Wrap string or strips of leather around the handle, if available. Paint the product in the color you like.

Plywood sword step by step.

Do not forget that it is better to smooth out the edge. A child may inadvertently get hurt or cause irreparable damage to a friend. Be careful.

Cardboard sword

You can quickly make your own toy for a little boy from cardboard:

• You will need a sharp knife, scissors, paint and a brush;
• a sketch of the future product is sketched on thick cardboard;
• then we cut it along the contour;
• We paint the sword with paint, and if desired, the blade can be wrapped in foil.

There is simply no simpler option.