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How to make a sword
This a complete tutorial on how to make a sword. A pretty good sized and solid sword. I show you everything from start to finish.
And I also have a video tutorial that you can watch. It is at the bottom of this page.
Will has a youtube channel with over 800 videos on projects you can make. Check it out right here
It needs but one foe to breed a war, and those who have not swords can still die upon them.
Tolkien
Here is a look at the sword we make in this tutorial. You can see a 12 inch ruler to give you a size comparison.
This is a closeup of the handle.
First Let's Look at the Materials -
I used a piece of O1 steel for the sword. It is a steel that you oil quench. Typically this type of steel is perfect for knives and shorter swords. I used it to make a longer sword and it is quite good for it. Very sturdy and strong with some flexibility.
This picture shows the exact steel that I bought to make this sword. It is available on amazon.com:
The Handle - I managed to get a bunch of pieces of wood for turning. If you are making a sword just like this one you are going to need a piece of quality hardwood that is at least 2x2 inches and 7 inches long. Here is a good example on amazon::
About the Pommel - The picture here shows a disc of steel. The diameter is 2 inches. I have a rod of steel and I cut off this slice that is 3/4 of an inch thick. this is what I used for the pommel of this sword.
That can be a bit of a challenge if you don't have the tools to cut something like this. I have a friend who works in a machine shop and I asked him to cut this disc off the bar for me.
You do have the option of using something else like brass which is much easier to work with.
They don't sell this on amazon.com the last I checked but you can get it at MSC or maybe Grainger. Same goes for the brass.
Here is another sword. It has the brass pommel. So the brass really does look great and it is much easier to work with.
The Cross Guard of the Sword
The Crossguard is a single piece of O1 steel. I bought a bar of it. There is no need to forge this or harden/temper it. It is easy to work with files and emory paper.
The size I use is 1" wide and 1/2" thick. I bought an 18 inch length of it but only used 7 inches for this piece.
I checked amazon.com for this exact steel that I ordered. They currently do not have 18" lengths in stock but they do have a 36 inch piece.
One last piece of material is used.. That is the pins for pinning down the crossguard and the pommel. I used 1/8' inch steel rod stock. I picked mine up at a hardware store. Hardware stores and places like Home Depot will have a rack with all kinds of steel and aluminum rod stock.
Looking for instructions in bladesmithing that'll put you on the cutting edge of the custom blade market? Then this definitive guide to forging world-class blades is for you. Written by a master bladesmith, this book tells you how to set up your forge, select your materials, fashion grips and hilts, grind edges and much more!
This book will get you blacksmithing fast and easy. It is an introductory guide to blacksmithing for people who have little or no experience with the craft. It explains with 50 pictures and illustrations what a forge is, what the tools are, the parts of an anvil, and how it all works. It also shows you the things you will need to get started and where you can get them - and even how to make your own simple forge if you need one.It is a complete introduction to blacksmithing that includes a series of tutorials with pictures showing you step-by-step how to perform basic blacksmithing techniques like pointing and bending. Written in an easy to understand style this book explains to you why the blacksmith heats steel and why the changing color of the steel when heated is important. You will gain an understanding of what blacksmithing is and what the basic techniques and fundamentals are. And this will give you a solid groundwork for moving forward into creating a wide array of objects, tools, and items. This book will give you the confidence and knowledge you need to start hammering hot steel into shape.
Knifemaking for beginners - (Another of Will's books) Teaches you how to make knives from beginning to end. This book is for beginners who want to know how to make knives but don't have any blacksmithing experience; And you don't need a forge or an anvil for this.
We would be hard pressed to think of a more versatile or effective sword than the "Bastard" or "Hand-and-a-Half Sword" we offer here. For a sword of this size, it's amazingly light and fast and tips the scales at approximately 3 lbs. Its 33 1/2" long blade is quite wide so it can produce deep shearing type cuts yet pointed enough to be effective in a thrusting attack. Its long handle is suitable for both a one or two handed grip and is fashioned out of wood covered in black leather. To balance the long blade we have capped the butt with a beautiful "scent stopper" pommel which can be a lethal weapon in its own right.
Few historical icons can match the evocative power of the medieval suit of armour, and this epic new book is a complete course in the tools and techniques of the modern armourer's art. Through more than 1,000 detailed photos and clear instruction, Brian Price presents a working handbook for aspiring and active armourers who want to develop their skills in the production of medieval armour in the style of the 14th century. The book is divided into four sections: a sweeping history of armour and its production from its medieval roots to its modern revival; a practical introduction to all the tools and supplies necessary to equip a modern workshop; a thorough review of key techniques; and a series of actual courses in constructing armoured defenses for the head, body, arm, hand and leg. Taking the reader through the construction of an authentic medieval harness from conception to completion, Techniques of Medieval Armour Reproduction is a vital addition to the libraries of serious craftsmen, historians, collectors and researchers.
The Handle - I managed to get a bunch of pieces of wood for turning. If you are making a sword just like this one you are going to need a piece of quality hardwood that is at least 2x2 inches and 7 inches long. Here is a good example on amazon:: 
About the Pommel - The picture here shows a disc of steel. The diameter is 2 inches. I have a rod of steel and I cut off this slice that is 3/4 of an inch thick. this is what I used for the pommel of this sword. 
Knifemaking for beginners - (Another of Will's books) Teaches you how to make knives from beginning to end. This book is for beginners who want to know how to make knives but don't have any blacksmithing experience; And you don't need a forge or an anvil for this.
