Mini Sword

In this Instructable I will show you how to forge and finish a tiny sword from a nail.

The first step is to ready the charcoal. This step is optional, because you could really just use a propane torch to heat the nail. I used hot charcoal first, and it didn't really work, so I just used the torch. Next, draw the design for your sword.

Before you begin forging, mark where you want the blade to start and the handle to end. Using the torch, heat the nail until it's red hot. When it's ready, quickly grab the nail on the head end with some pliers and take it to the anvil. Hammer the metal flat, but not to where it's too thin. Go back and forth between hammering and heating, until it is straight and flat, leaving the handle end (the head end of the nail) intact. When it's the right shape and thickness, cool it off with water.

Mark again where the blade begins and the handle ends. Using a belt sander, 120 grit sandpaper, file the metal until there are no dark spots left. Be careful not to thin the sword too much. Then taper the edges from the middle out on both sides. Next measure how long you want the handle to be and cut it to size using bolt cutters. Then sand the handle until the dark patches are gone. Shape the handle, tapering it down from the blade and rounding the edges.

Mark a line in the center of the blade. Using a Dremel/rotary tool and a diamond tipped bit, carve out a line. Leave the same amount of space from the tip as is from the sides, and go all the way through to the handle.

Using knife sharpening blocks, files, etc., sharpen the blade and polish until smooth. Start with a larger grain, then move down smaller and smaller grains. Smooth the blood groove in the center, blending it into the blade until it looks nice.

For the guard I am using stainless steel wire. Start with a straight piece, about 2 inches long, and bend it in half. About halfway, bend it again perpendicular to the first. Repeat this until you get a result similar to the picture above. Then slide the guard onto the blade, and super glue it down. Clamp it and wait for it to fully dry. When the glue is dry, use pliers to bend the wire into a spiral shape on the blade, and glue it down as well.

Glue two diamond-shaped jewels to the tip of the handle, one on either side. Then take a thin strip of leather and wrap the handle. I spiraled some brown twine around the handle as well. Glue down the ends and let it dry completely.

The sword is now finished! I think it turned out pretty good, and I hope you enjoyed the Instructable!