Metalworking

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I believe I have developed a new obsession: Metalworking. It started innocently with chainmail. Then my brother and I built a pit forge where we started forging steel. We have yet to finish anything because the fire tends not to get very hot (we haven't really got it set up right), so it's a slow process. But in the mean time, I'm cold forging some splinted armor.

Today as I was working on that, I finally got around to fixing a broken key, metal-smith style, and fully documented the process for anyone else who might have a broken key (or whatever). Then I got bored and made this miniature sword:



It's about 3 1/2" long. I still need to add a guard and wrap the handle. I consider it practice for when I get tho forge set up properly and make a full-size one.

But anyway, I'm suddenly feeling very productive. I want to do more, but it's too late today. I'd keep everyone up all night with my hammering. So, um, there you go. More proof that I am obsessive.

I've never done any actual forging but am experienced in using an oxy-acetylene torch and it is possible to heat steel with a torch red hot which makes it amenable to shaping with a hammer and anvil and might be easier than actually making a forge furnace. Also welding and brazing with a torch makes assembling easier.

Cool stuff!

It was always a dream of mine to do blacksmithing and making blades. ONe of these days maybe I will have the space and the money to set up a smithy and start teaching myself a little bit.

How do you go about making the chain mail? I would be interested to see the process behind it.


john

I'd always wanted to make my own skateboard trucks but was never obsessed enough to do it. Now that my full-time interest is music-making, I probably won't take on the risk of injury that's inherent to metalwork.

I thought of that too for smaller pieces. I just haven't gone to get one yet. I'm not sure it would work for bigger things, though, like if i were making a full-size sword. That's one project I haven't attempted yet.



It's really pretty simple. It basically involves winding wire around a metal dowel to produce spring-like coils, which you cut apart into rings. Then you stick them together. There are tons of sites around that will tell you how to do it in more detail, but THIS ONE is probably the best place to start.



Now that sounds interesting. Making a good one would probably require casting or machining metal, though. Casting aluminum is something that pretty feasible. I actually switched to using a grill as a forge and accidentally melted off some aluminum fasteners that were holding a logo plate onto the front. Then I threw in the logo plate to see what it would do, and it dripped out the bottom of the grill. So a good fire will have plenty of heat for that. Most of the difficulty is in making a good mold and getting a hold of a suitable vessel for holding and pouring molten metal.

I guess it's entirely possible to smith one from steel or something. I just wish I had a better anvil for those kinds of things. I've currently just got a bench vise and a baseplate from a railroad track, which is good but not stable enough.

Also, I've only ever burnt myself once when a piece of steel bounced off my baseplate anvil and grazed my hand. And it was such a minor burn I couldn't find it an hour later. In cold metal working, the most I've done is scratch my knuckles when a file slips. Both can be pretty dangerous if you're careless, but they can be done safely if you're reasonably careful.

You should look into the way Japanese swordsmiths make their swords. They take steel and fold it many times and beat it flat to make especially tough stuff that holds a fine edge. See http://www.samurai-sword-site.com/Japan ... aking.html
It's similar to the baking method of making puff paste but with steel instead of dough.

The only metalwork I ever did was brazing, sheet metalwork and casting. Haven't done any forging.

You should look into the way Japanese...
DAMN, Sand beat me to it



@Wurd, that's Awesome, are you doing just as a hobby or is it your profession?

OH, and scew the Japanese. Make a saex out of that. And then make a francisca.

Yeah, I had the basic idea of how Japanese blades are folder. I'll probably try it out eventually, but the one I showed above is more of a novelty. It's too small to use, anyway. As I said, it's a miniature, only about 3 1/2" long. I do plan to make full-size swords, and maybe I'll fold them, but I'll probably end up using European methods.



Well, right now it's just a hobby. But I know I could make some money this way. I've just been experimenting to figure out what I can do. And as an artist, I need to figure something I can start producing for profit.



I've never really liked the shape of the seax. But a francisca, that would be interesting.


I also totally forgot to mention I've been making copper guitar picks, but I don't have any photos of those at the moment. They may be a little hard on the strings, but they are cool and sound great.

It's double-post time because I just finished this today.

always wanted to try that; sounds cool.

All I know is that blacksmiths say you'll go to hell if you work cold iron...

I have a vague idea how you make chain mail, except for the patterning and riveting the mail together would take more coordination than I have...

Eventually you could try articulated plate..

Actually, there are armorers out there who make good money off the SCA crowd...some of these creations go for thousands...

If you live anywhere near New York City try to get to the Metropolitan Museum in Manhattan. It's got a great collection of armor and weapons.

Indeed, cold iron would just break. But steel is quite a bit stronger and gets harder as you work it cold (until it also gets too brittle and breaks).



I don't rivet mine. Too much work. I'm still working out how to punch the holes without splitting the wire open. I have tried flattening rings or just overlapping the ends with favorable results. Here my first attempt, which turned out quite well:





Yeah, after I get by splinted greaves (legs) and vambraces (forearms) done, I'll probably do articulated spaulders (shoulders). In the mean time I'm working on my chain, and I hope to be able to sell some. I just started a coif yesterday. I figure I can have it done in a couple weeks.



Unfortunately I don't, but I'd love to go there. I've seem some late period armor in the Art Institute of Chicago Museum.

the mini-sword you made looks a bit like sting from Lord of the Rings!

i want to get into sword fighting or fencing but there isn't anywhere near me that teaches that...
your work looks awesome so far....keep posting pics!