I'm Matt I'm Kerri we are the stag my brother is a Baltimore knife and sword we're going to
be building some of your favorite weapons some weapons that you've never seen before this is
man-at-arms reforged I don't know about you guys but when they announced that there was
going to be an animated series of Castlevania I was pretty excited I grew up playing the original
Nintendo video game and there's a lot of cool weaponry a lot of nice fight teams in it in
this episode we're gonna be making a low cards heirloom sword this is his favorite sword and
historically this sword would have been considered a nest Ock has a very thin blade very long very
lethal for both slashing and piercing so we're gonna be forging this plate gonna be awesome
for the card on this sword we're gonna do something we don't always do which is we're
gonna almost completely turn it on a lathe even though this does not have a completely
round form in the end I'm gonna start this way because we've got these nice Peaks in a leaf
turn section you're gonna see it basically as round objects that are turned sometimes
you're gonna see some faceting and Matt's gonna make some decisions how he's gonna lay that out
but I'm gonna get that basic form done for him it's gonna be lathe turned on both sides the
center block which will be round will take to the middle will cut it flat and make the slot
for the plate to go through and things like that matt'll get into it and get it completely right
even though I finished the form on the lathe and went through and polished this piece it
needs some faceting work Matt's going to be able to do this on the smaller wheels
on the sander we'll go through create this flat surface and then re polish
for this heat-treat we're doing something a little different normally you always see me
or someone else rough grind the blade before we actually do the heat treat in this case we're
taking the blade straight from being forged right to the III and the real main reason
for that is to try to keep it as straight as possible this is a long narrow blade we don't
really want to cry too much material off of it and risk a chance of warping that'll be
a real pain in the butt to fix afterwards so instead of having nice soft material to
grind on we're gonna put in the extra effort to make sure this stays nice and straight
working in a fairly large piece of steel Tanner begins cutting the pommel it's going
to be made in two separate sections the primary reason for this is Matt's gonna
come back and do the faceting on the lower piece while it could be done all on one
piece it'll be far easier if there's two and we can then put them together
so we have our two pommel pieces that tan or turned on the lathe the next step is to take
this piece which I'm calling the either collar or the rondell piece and just add fasts the top of it
I'm going to change the big wheel out to a really small wheel to get on the inside and add facets
all right go up there heat treated and now tempered this plate and I have to go through
repro file a tip and start grinding on this now what I'm looking for is what we're calling a
diamond cross-section which I do on a rapier on a regular basis also going to do it this
still taper which means it's going to be thinner towards the point than it is towards the guard
so for the overlay on this sword that goes down the center it sits on the guard bends goes down
the blade has a fair amount of different plate changes and then you see the cross kind of down
the center of the blade maybe it's an etching maybe it's right on the surface we're gonna create
it all as one piece in 3/16 rather than using the CNC plasma table I'm going to use this milling
machine mainly because the milling machine will give me sharp corners I've already cut one out
you can see how pointy it is it gets down pretty small in here and across it's got a lot of detail
in the form so I'm going to cut the second one out so that we've got both sides of the piece then I'm
gonna hand them over to Matt he'll attach them to the guard and grind a bunch of different form
and we'll get it laid over the guard and blade and then be able to polish the whole piece out
all right bill did a great job hogging off a lot of material doing the rough grinding on our blade
it's now time to move on to the finish grinding and then under the polishing he was using a 24
grit belt I'm gonna start with a 60 grit Duval them do a 80 120 220 and then our final polish
would be a scotch-brite now the edge wanders just a little bit in some spots so you're gonna see
me start off by taking material off just to get that edge properly aligned on both sides
then I'll move on to actually doing the bells now when I do the actual bevel
grinding they're gonna see that I'm doing something kind of unique I'm not going to
just do straight up-and-down passes I'm going to be going at a 45 degree angle if both left
and right and the reason for that is I want to try to get these devils is perfectly flat
as possible and when you change your angles up when you're grinding you're getting all
the little dips and grooves sanded completely out and then we move on to the actual policy
man is now gonna create the final form of these overlays he's got to go through and
grind and create different surfaces than the ones that I cut on the mill
it'll be quite different once he gets in fit to the blade
using the drawing dies on the iron kiss Illya now begins to cold Forge the pipe
that's going to allow him to give some shape to the handle before we begin doing the detail work
now that Ilyas forged our pipe handle the shape I've gone through and almost
polished it all the way out before I get it completely polished and smooth I have
to add kind of a loose spiral to the entire thing I'm gonna do that using an air wheel
with the surfaces cleaned up we now polish the handle
when we first considered making this sword who thought it was a rather simple piece but
once we got into the build we realized there's a ton of detail on the hill and
every piece had to be polished and though the sword blade looks very simple had to
be ground just right to get the right look and to make sure it performs well I think
we all did a stellar job and created a sword worthy of being called an heirloom
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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 next