Swords were used in various cultures.
Swords have been used as weapons and tools for centuries, and throughout the duration of the popularity of the sword, there were sword makers who profited from the demand of such weapons. Sword makers must first design, chisel and grind swords before they are prepared for the fires of forges. Though there are still professional sword makers today, some hobbyists may desire to make their own swords for forges.
Instructions
1. Determine what type of old-fashioned sword you would like to make. There are many types, some more difficult to make than others. For example, something with a curved blade, such as a scimitar, flamberge or shamshir will be difficult to make, while something with a straight, solid blade, like a dirk or longsword may be easier. Some swords, like sabers, are only slightly curved.
2. Lay out your wedge of steel and with a piece of chalk or a pencil, sketch onto the face of the steel the design of the type of sword you want to make. It make take a few tries until your sketch comes out how you want it. Retrace the sketch with permanent marker so it is not easily wiped off during the process.
3. Drill holes into your steel along the outside of the outline you have sketched. The holes will make it easier for you to cut away the excess steel later. Be careful not to drill too close to the outline.
4. Practice with your angle grinder, cutting off pieces of steel far away from your outline. When your precision improves, move closer to the outline and cut along the sketch with your angle grinder. The holes that you drilled will make it easier to grind away tough angles in your sword. Use long, smooth strokes to grind the areas closest to the outline. When you have removed all excess steel and only the basic shape of your sword remains, stop grinding. Remove any minor excess with a metal file.
5. Draw a line width-wise down the center of your sword; use chalk or pencil for this so that you do not mar your sword. Grind the sword with the bevel, pushing it along the sword slowly, angling it at the edge of the blade and leveling it out towards the center. Move the bevel so that it travels the entire length of the sword with each stroke. Stop beveling when the edge of the blade is one millimeter thick.
6. Sand your blade with a belt sander until it shines. Your sword is ready for a forge.
