Trunks: So you wanna see my sword huh?
King Cold: Remarkable craftsmanship.
I'm Matt.
I'm Kerry.
We are the Stagmer brothers of Baltimore Knife and Sword
We're going to be building some of your favorite weapons
and some weapons that you've never seen before.
This is Man At Arms
Reforged
Dragon Ball Z is one of the most popular animes of all time
and it's certainly the most mainstream 'cause it was on regular TV
for a long time and most of us grew up watching it. Sam and I are both big fans
We debated back and forth for about a year who was gonna get to build this one we decided
let's just share it. So let's get right to the forging
One of the nicest things about these larger hammers is that we can use large round stock.
This is a far less expensive way to buy good material, in this case 1045
For the pommel on this sword, we're gonna be turning it. We've got some free machining material.
It's been laying around the shop for a while, so it's a little rusty on the outside. I'm gonna put it up
take a powered pass across the surface to make it smooth and clean
And then I'm gonna disconnect the auto feed and just freehand the entire shape
Prior to beveling the edge, Sam finishes much of the form on the Nazel creating the point and then cutting in the shoulders
Even though we're going to be doing a lot of grinding on this sword
We want a little bit more width
so Sam is actually going to start the bevels with a hand hammer
and this will drive more width as the material goes to the outside
Now that Sam's finished the forging on this blade, it's time to start grinding
I just wanted to point out a few distinct features on this that differ it from a normal western sword
One is the point not only the profile, but the grind on it would be different and the guard has a habaki
Really lets you know that this was a japanese artist that drew a Western-style sword
It's gonna be a little bit more of a challenge, but it's gonna be fun. Let's get at it
All right, so I have my edge bevels roughed in at this point
I went ahead and ground it to a diamond cross-section
Which is very typical on a western sword but like I said before the point of everything [dipper's] into a very Japanese-style
grinding but what I got to do is now take that central line and make a diamond
So I'm going to start my flat bevel from the point and push it all the way back
It's tricky and it's very technical grinding and it's going to be a challenge
Now that the rough grinding phase is complete Sam's going to move on to heat treating our blade.
In this case we already had our welding torch up to temperature
It's a little shorter than our heat treating forge
But he's just going to carefully slide that blade in and out until he gets an even heat and then quench
After the quench Sam removes the blade. He has a few seconds to straighten it
He's just kind of lay into it with his foot. Get it rough straight during the temper
we'll be able to get it nice and true
With the blade now to shape and the tang defined Sam now knows his portions for the guard
He's going to use the excess 1045 that he cut off from the blade forging and forge that into his guard
He starts by using a tool under the power hammer
to pinch some material he'll then draw that out by hand and then forge the round ends that we need
Since Sam only rough forged this guard to shape got to do a little truing on the sander
He starts on an 80 grit and works his way through
Sam's forged more 1045 blades than any of us in the shop
And he says after he treating that these blades only need a torch temper
He uses a torch and carefully heats the central portion of a blade
which is the thickest and has the most mass this will allow that heat to spread towards the edge
giving us a nice blue color in the center and a straw color towards the edge
I'm now ready to turn this bleed into its final form
We normally polish on progressively
softer wheels than on this we want everything to be super crisp
Want that bevel to really stick out and our lines to be nice and true
After marking the guard Sam now cuts the slot using the Gordon milling machine
After watching a few episodes some old-school Dragon Ball I noticed there was a habaki on the other side of the guard
We're gonna make this out of steel because that's what it looks like in the show
So I'm going to take two pieces of steel
I'm going to bend them over slightly in the vise to match our cross-section of the blade, and then we'll wall them solid later
After the guards been sanded through the grits
The last thing we have to do before we can assemble is turn those nodules down on the edge
just a little bit Sam's Gonna use the torch and a wood hammer and bend them on a slight angle
All right, I got my edges completely polished all the way through the grits
I'm really happy with it. The central bevel is so sharp it could cut ya, but
Not even in its final form yet
I have to refine that tip and then we'll be ready to assemble
All right, we got our habaki welded onto the blade
Welded the seams here, not only does that give us our nice
look, but it gives us nice clean shoulders for the guard to sit. So now my goal is to go to the 80 grit
I'm gonna clean the weld spots and then I got to make the central ridge on the habaki match the ridge on the blade
For the handle core on the Z sword I'm gonna be using some oak
Because it's gonna get wrapped in leather
I don't need to try and make it in two halves and make the seam pretty
So I'm gonna mill only one half of the wood to the dimension of the slot
Because the tang is tapered
and it's really hard to mill a taper I'm going to mill it in a stepped hole
I'm going to use a wide milling cutter the dimension of the tang up front
and then as I get down to this line here. I'm going to switch out the cutters to a smaller one
It'll get superglued roughly together to be shaped, and then it'll be finally epoxyed on to the tang and leather wrap by Kerry
After milling his tang recess and his two pieces of wood Sam clamps them together and begin shaping them on the sander
This is a pretty simple handle
We're gonna then cover it with leather later, but it still has to have the right form and the right shape
I'm now on to the final step. This is the same kind of leather wrapping I do every day on our regular swords
I'll be able to work right through this quickly
You guys have been asking for us to do some more realistic historical based swords for a long time
This one is not only a western sword, it has a lot of Japanese characteristics
So it was a whole lot of fun to make had a few challenges, and I'm really happy with it
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Thanks for watching man-at-Arms
Reforged we need to know what you want the guys to build so tell [us] in the comments below [what] weapons you want to see
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