Q&A for How to Make a Metal Sword Without a Forge

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How durable is this sword?

Community Answer

It is not very durable, as it is not heat treated or tempered. Only use this method for display pieces -- if you want a good sword, then use a forge.

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Question

What's a good steel for a beginning?

Community Answer

Carbon steel 1045-1080; stainless steel 440 a, b or c for a knife, but no sword longer than a foot 316 to make something that won't rust. Anything made of tough steel (impact resistant) that has not suffered too much wear and tear.

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Question

Where can I get the metal to make the sword?

Community Answer

A junkyard or any place storing old cars would be a good place to start.

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Question

What are the best metals to make swords?

Community Answer

Carbon steel is a good metal and is used frequently for high-end swords, but for this build, I suggest metals that are easier to work with - such as aluminium and stainless steel.

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Question

Where I can get the folded steel?

Joshua McKinney

Community Answer

At a metal smith shop, or if your really dedicated, a junkyard - but be specific if you go with this option.

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Question

How dangerous is it if it was properly made?

Community Answer

It's mostly for display, so it's not as dangerous as other swords - but it can still be dangerous, depending on how sharp it is.

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Question

Will it slice through anything?

Joshua McKinney

Community Answer

It depends on the type of metal you used and the material you're cutting through.

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Question

What if I don't have all this stuff?

Community Answer

Buy the the bench grinder, or file. You might find the metal strip at a junkyard.

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Question

How long should the handle be?

Community Answer

It depends on your hand size. The handle should be about two inches longer than your clenched fist.

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Question

How could I make a sheath for it?

Community Answer

You can make a sheath out of just about anything. Since this is a display sword, you might want it to be fancier. You can take the easy path by sawing a cane nearly in half and gluing 2 strips of wood or sewing a wide strip of leather to it.

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Question

How long should my metal sword be if I'm making it without a forge?

Community Answer

It should be the same as a normal sword, maybe a bit smaller.

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Question

How do I make such a sword more durable?

Community Answer

If you have a torch, you can “heat treat” it before sharpening by running the torch across the surface of the sword. You have to do this carefully, as too much heat can be worse than too little. Too much heat will actually make the metal brittle and therefore easier to break. Depending on the type of metal you use (and you can easily look up specs on how much heat it can take), you can set a fire to a few logs and dip your sword metal into the hot coals, again being careful not to apply too much heat for too long.

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Question

Is it legal for me to own a metal sword I've made?

Community Answer

It depends on where you live, each country has its own laws. You may be allowed to own it in some parts of your country, but not others. Check your local laws first.

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Question

What do I do if my parents won't let me make a metal sword?

Community Answer

Try working with foam instead. Since this is for display purposes, it won't matter very much if it isn't functional. Foam is easier, safer, and cheaper.

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Question

How do I drill holes in carbon steel?

Community Answer

You can use a drill press, or any other heavy duty drill. You could also hammer it into the pointy part of a anvil.

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Question

I need a something worthy of a hobbit sized adventure. I don't have any fancy grinders, but I do have hammers and metal. What could I do?

Community Answer

With enough persistence, you can gradually hammer it into shape. You can buy concrete, wood, and sandpaper to make a cheap grinder, but it probably won't last very long if you use a harder metal.

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