Cutlass build - Group WIP

[Athenas Edge]

This looks awesome JT! I've never made a sword yet, but you make me want too.

 

[JTknives]

It's a fun process

 

[JTknives]

Getting closer.

It was time to cut the tang slot. I marked out the center line and center punched alobg this line so I could drill a row of 1/8" holes.

After drilling I used a 1/8" carbide burr in a dremmel tool and removed the webs between the holes.

I now use 2 strips of hardened D2 and clamps to create a slot guide. I use calapers to adjust the guide blades to be proper width.

After some time with a file everything fits perfect and tight.

Next I needed to tackle the wrought iron etching.

 

[JTknives]

Ok guys all the components are done and ready to assemble. I was not happy with the etch on the blade so I re etched it.
After etching I put the guard and pommel in a vibratory tumbler with abrasive sand. This clears out all the gunk from the wrought iron and really makes the grain pop. Then I use a stainless steel fine wire brush and mineral oil and scrub it down really good.

So that's it for now guys. It's getting assembled tonight and will be over night shipped to the customer in the morning.

 

[Dago Red]

That's just beautiful, the many hours of hard work are obvious. You outdid yourself. I bet there's some excited guy somewhere taking a day off work tomorrow so they can be there when it shows up.

Red

 

[Ken H>]

WOW!!!! JT, you outdid yourself! That wrought iron really pops and truly makes that cutlass standout. I'm not at all surprised that cutlass is sold before you even get it finished. Congrats. Be sure to post some finished photos.

Congrats on a job well done.

Ken H>

 

[Ghostman3]

That turned out awesome. Wow!


Sent from my iPhone using Tapatalk

 

[Dago Red]

Hey guys, hopefully this isn't a hijack, I'll post my own thread w pics later this weekend but can't resist chiming in.

By a fortuitous set of events (cliff notes) I was jonesing for a Seax a couple months back and found one Jarod had made months before and still had available. We already made a deal in that. Same time I'm planning a pirate themed murder mystery party and start looking for a. Sword for my costume. I stumble on this thread and email Jarod about the sword.

I'll save how great he is to work with for my other thread. For this one I want to say that I unboxed it today and the pics don't do it justice. First off, this thing is a beast. I'm a good size guy (6' 250) and this thing looks right in my hand. The grip is big, the guard beastly, the pommel "brutal". The aging looks amazing and the fit and finish are a give away that this is way more than the vintage blade it appears to be. The cutting edge is a hair over 23" (total blade just over 24"), but it's light, and sings through the air. My wife had no idea I'd done this (and wonderful woman didn't even ask what I spent) and when I showed her she started talking about zombies. I feel I could cut quite a swath before my arm even got tired.

My buddy was there when I opened it and freaked a bit when I said I was gonna start cutting stuff. He said it was too nice and should only be displayed.

Even though I've indulged most of my wants over the years this was my first sword, and the smile it put on my face was worth waiting so many years. Jarod was great and worked his ass off to get it to me in time for my party. I can't wait to do more projects with him.

(And JT, thanks for the warnings about not killing myself, it IS sharp and shaving the last few hairs off my hand with it took extra concentration )

Red

 

[JTknives]

Thank you Red for the kind words, a lot of hrs did go into this child of mine.
Here are the finished pictures. I was not able to get a lot as I was snapping pictures while the wife was making a box and getting the packaging ready to ship out in 1hr. But we made it and I ended up with a few good pictures.

 

[OccamsBlade]

That truly is epic, man. Looks like a piece of history.

I like that you referenced East Inda Comapny. I've been watching Taboo. Would like to learn more about the history of EIC myself. Just have to finish reading Washington's Immortals first.

 

[S.Alexander]

I'm getting close on my cutlass. The blade is heat treated which I have pictured below. I have since done the finish grind, and just have to do some hand finishing.



This is the handle. It's a nicely figured piece of horse chestnut. I also have the D guard shaped. I just have to put a brass plated finish on it.

 

[S.Alexander]

Here's the D guard all shaped and drilled. The tang is threaded and will hold everything securely in place.



Here's the sword all mocked up before it gets epoxied and secured.



A closer view of the handle during mock up.

 

[S.Alexander]

Ok here are my final pics. I had a "design change" at the pommel, so I decided to add a domed pin through the handle as well. The guard was heat colored and brass coated using a brass brush. It has an interesting patina to it.

I also made a leather scabbard, that I hardened with hot water and beeswax. I fits very securely in the scabbard.

 

[DEllis]

Nice work Shane!
Can't wait to swing that thing around and scare potential customers away from your table in Kamloops ARR!

Darcy

 

[Ghostman3]

Wow looks fantastic. Really talent in here.

 

[S.Alexander]

Nice work Shane!
Can't wait to swing that thing around and scare potential customers away from your table in Kamloops ARR!

Darcy

Maybe I'll just walk around with it attached to my belt... It IS mainly a gun show after all