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Photos of progress - Doug Ayen's Blacksmithing Blog [entries|archive|friends|userinfo]
Doug Ayen

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Photos of progress [Aug. 27th, 2009|12:28 am]
Doug Ayen
It took a lot longer than I had anticipated, but the sword is now all straight and true, or at least close enough. The original blank was about 14" long by 2" wide by 1/4" thick; the current size tapers evenly from the tang to the tip both in width and in thickness, with a length over 32 inches, less a couple of inches that will probably be removed during grinding, as the forged blank doesn't quite match the final design. It's 3" wide at its widest.

The even taper was the hardest part, and the tool that allowed me to do that was the rolling mill I'm now trying to ressurect. Even so, forging this out took many hours, and the rolling mill only helped in as much as it made drawing out the piece more controllable. Keeping a long skinny thin piece of steel at forging temperature while working with the mill was difficult, you had to pre-set your gap, as it took a wrench to adjust them, and if you got one side lower than the other, the work would warp and likely jam. Still, it beat hand hammering, of which there was a great deal as well in getting the handle and bevels in.

These are pretty rough, just as-forged with the scale knocked off with a bubble belt. They are a truly wonderful invention, a coarse ceramic grit formed into a series of thick bubbles on the belt, that do an amazing job at removing mill and forge scale, while sucking at doing anything else. Profiling and all grinding and polishing operations are yet to come.

pics at:
http://www.homeport.org/~ayen/photos/chefsword_1.jpg
http://www.homeport.org/~ayen/photos/chefsword_2.jpg
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