welcome to the man-at-arms black market if you're here for the Fury song you're in the right place
I'm Matt I'm Kerri we are the stag my brother's a
Baltimore knife and sword we're going to be building some of your favorite
weapons some weapon you've never seen before this is man-at-arms reforged
right in the middle of deciding what to filled this season call of duty drop the fury song
we knew this is a sword we were going to have to build we began looking at a way we could also make
it bulletproof okay so I have the blade picture fed into AutoCAD doing tracing of the perimeter
right now then I'm going to hand it off to Kerry and John they're going to go ahead and get a
program down there and get a cut out and see and see you size the blade to 35 inches in the game it
looks to be like a one-handed sword but we want to make it really big and bad it's still going to be
a one-handed size but it's going to be massive it's going to do a lot of damage so I'm going
to go ahead and pull just the blade portion out here so you can see it clean this up a little bit
boom it's ready to cut it out on the plasma since our Call of Duty sword is a modern
build we figured it'd be pretty cool to cut the blade out of some modern material here
we're going to use a sheet of AR 500 which is abrasion resistant ballistic sheet steel
basically bulletproof armor plating so due to the expense of cutting out of that we
went ahead and cut a sheet metal template as a dry run make sure everything turned out okay
the way we want it everything looks good so now we'll go ahead and cut the real thing
this is actually the first time we've plasma-cut ar500 we have to
use the plasma because this material is very difficult requires carbide cutters
we're like plasma cut out okay now let's see if Matt can grind this all right we got our
massive blade cut out now get ready to start grinding I've never ground on this material
before really don't know how this is going to grind but what I do know is this material
is extremely abrasion resistant so what I'm going to use is our brand-new klingspor belts
they're ceramic belts so they're really evil one thing you have to do when you're using
these belts is make sure you have a respirator so we're going to start tackling this thing
now I'm going to start by profiling and I'm gonna get right into doing some edge driving
grinding pre hardened material very important to keep it cool
not let it overeat and ruin your temper so I'm going to cool and a lot more off
than normally would on man-at-arms and I'm just gonna stay at it keep it nice and cool
I need a little break so I'm going to hand it off to Kerri to do the machining of the word
olimpio on the flat Oh blade all I got to do is do a little tracing and then hand that program
off to him and he'll get it carved out see what we got looks good to me so doing this engraving we're
going to start with a fairly small cutter we're going to go very light on our depth do a couple of
different passes I have an odd feeling that we're going to dull this cutter pretty quickly and then
once we have the depth of the piece we'll put a brand new cutter in and sharpen up all the detail
all right at this point we now have the bulk of our edges ground in carry we went
ahead and milled the Olympia on the flat of the blade looks really good now I got
to really slow things down and take my time and do some more of the intricate grinding
on the spine here I got to start adding these back bevels on each one of our serrations I'm
gonna go to the 80 grit instead of the 24 grit and make those bevels nice and perfect
it's now time to start the guard portion of this sword build I'm gonna work from a
different drawing because this drawing is all Fang a little bit it was easy enough
to do the math and calculate and make the blade work but for the guard it's
gonna be a little bit of struggle so I'm going to use the attach command
kind of good screenshot of the guard it's a nice flat dead-on picture I'm gonna go ahead and start
tracing that I'm gonna go ahead get those cut out on the plasma cutter get a little shape to
them ball them on and it'll look like one fluid piece and it'll be awesome now we've cut the first
half of the call of duty guard everything fits up real nice we're going to hand cut the other hand
alright my next step is to start removing some of the dross left from the plasma-cut
then I'm going to move to the slack sander I'm going to bevel all these spikes it's
gonna add some more depth to that look to make them look a lot more aggressive
all right my next step that I have to do is use my handy-dandy handheld belt sander to
go ahead and start cleaning up this inside ring gotta take off this little nip that's
left from the lead and lead out from the plasma cutter and just blend this whole thing smooth
alright the next thing I have to do is remove the amount of material that's left from the
lead and lead out inside our grooves on our blade I'm gonna start with a carbide cutter
on a rotary tool it's just going to save me a lot of time then I'm going to clean everything
up with a file so on this sword I know you've seen there's a very bright blue ring here we're
going to be using this LED headlight ring it's a 70 millimeter ring so it's a bit larger it's
going to sit from behind then we're going to use this acrylic we're going to cut a new diffuser
that fits in here that'll allow the light to show through past from where the metal is
all right so I now have the base of my perimeter bevels all established it's time to start working
on some of the more risky parts got again on this little groove and add some bevels all the way
around I'm going to do that using the slack sander it's kind of dangerous I'm gonna have to stick a
really sharp blade all the way inside this machine so I'm just going to take my time and get at it
so on the sword with the light we need to relieve a large area here so that the
light ring can fit in and I can put it in the plexiglass I'm using a solid carbide cutter
on this abrasion resistant steel I've done some test cuts it's actually very abusive to
the cutter so I'm going to use a roughing cutter you can see the little grooves in
it allows it to really take out the material hog it out and then I'll use this finishing
cutter afterwards I'll go back and recut everything to give himself a nice smooth area
with the two guard pieces clamped to the blade I heat up the tips with a torch and bend them
over to shape they're now ready have the ends welded and become one solid piece
so I've already run most of the edges through the grits at this point boy
this blade is depicted in the game the edge has really rough grit left in it
I could leave it like that but we want this thing to really slice so I'm going
to polish through on the 220 move to the scotf right and then it'll be good to go
in the game this sword has a very tactical handle we're doing two pieces I'm going to
use a polyethylene high-density plastic I'm going to sandwich that around the tang then I'm going
to use some thermal plastic also known as worbla to wrap around and create our second level we're
just gonna trace it twice because we're going to sandwich the handle so we need two pieces
like that now I'm going to move to our little mini van Saul here and just cut two slabs you've seen
us use a narrow wheel on our grinders to do a lot of detailing in this case I'm going to use one of
those wheels with a flat surface and just hog some material off where our Tang needs to fit
okay now that I got my Tang recess sanded on both sides and all the way through I clamped
the two pieces together lined up those two slots now we're going to start shaping it
but my handle shape now roughed in I can move
to the narrow wheel and start adding in those little grooves
once I get my overlay added this handles gonna be spot on examining
our 3d rendering of this blade I now know exactly the pattern I have to let on our
worbla before I can start cutting now I got my template all worked out I'm gonna
heat this up with a heat gun and just format the shape you can see as I heat
it up on the low setting of this heat gun it goes from a stiff plastic to almost liquid
all right so I have a little access to trim I'll use a razor knife get in there trim that
off do a little shrinking in some parts but uh yeah really like the way that looks so we
finally have all the components for this sword together light diffuser that I leave turned
this is our overlay plate holds everything in place wires have come up the handle you
can see the glow will mask this off so nothing shows and it'll give us the look of the piece
handle in place just a couple more fittings we're good to go even in the shop where we
work with so many different materials working with this AR 500 plate was quite difficult from
the grinding to the milling the welding and finish work in the end we were quite glad to
be able to add both the AR 500 plate to our list and the fury song to our arsenal yes
you
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