First Sword ever - suggestions on how to make a brass guard?

Col Defender

Col Defender

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Nov 11, 2011
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A good customer wants me to make a two handed Chinese War Sword for him. So here it is, just roughly cut to shape. The problem I have, which I just realized, is that I cannot go with a slotted brass guard (unless it's in two pieces) because the waist of the sword is so much thinner than either end of the steel will be. Suggestions?

 
You could make it a hidden tang.

You could make brass bolsters.
 
Frame handle construction, two piece guard, or change to hidden tang design are your options. You could also do a bolted on pommel.
 
The guys have given you the choices.
For simplicity, make the guard portion as two bolsters pinned together with several brass pins . On your sword, I would take the bolsters up about 1" up the handle above the guard flare. I would also have the same amount of drop to the pommel. This will make fitting the handle and getting a smooth transition simpler.
 
Stacy E. Apelt - Bladesmith said:
The guys have given you the choices.
For simplicity, make the guard portion as two bolsters pinned together with several brass pins . On your sword, I would take the bolsters up about 1" up the handle above the guard flare. I would also have the same amount of drop to the pommel. This will make fitting the handle and getting a smooth transition simpler.
Click to expand...

Thank you Stacy. Since I have never made a two piece bolster, and actually only a few bolsters at all, would it be simpler to have a left and right bolster, or a top and bottom bolster. What is on my mind is how I will get all the joints flush and minimally visible and how I will get a good fit between the bolsters and the knife tang. Thanks!!
 
I fit bolsters in a very similar way to fitting scales. Rough cut them out, transfer holes from the blade to one bolster, then the other. Pin the bolsters together temporarily in order to finish the top surface and bottom surface together. Then pin them to the blade permanently by swelling and peening pins and grind to final shape.
 
Thanks Kuraki - so if I understand correctly you have a left and right bolster, not top and bottom?
 
I'm not sure I understand your guard/bolster shape. Is it the delta shape of your tang at the end of the handle, or were you planning something larger?
In bolsters, they are the size of the tang. On your blade, they would be delta shapes with an extension running up the tang a bit ( sort of a "T" shape). You cut out rough blanks that are a tad larger than the tang ( just trace the blade on the brass) and they are drilled to be pinned onto the tang. You slip the pins in the two pieces and true up the front ( like you do with scales), and then pin them on the blade. Once secure, you shape them to the tang like it was a scale. Pommels can be made the same, and would match.
 
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