Thanks for all the kind words! I've never written a "tutorial" before, but I'll try to describe what I did. It's not too complicated.
One of the first things you may find is that these suckers are rather awkward to hold onto while you hit them. I use a pair of "nippers" (nail cutters) with a V shaped notch filed out of the middle of each jaw. This allows me to grab it from the head end the nippers fit around the head and the V grabs it by the corners of the spike.
I have been forging the blade to shape first, then twisting the handle, but I'm thinking it might be better to twist the handle first. Its just basically a lot of hammering to flatten the thing out to a proper blade witdth and length. If you start hitting it on one of the corners rather than the flat side it will give you a bit more width.
After I get the blade forged to shape, I heat the handle up then clamp the blade in my post vise and put a 12'long adjustable wrench back near the pommel and begin to twist. When it starts to cool stop and re-heat. It usually takes 3-4 heats. For right handers I use a clockwise twist as it gives a nice "thumbrest " on the left side of the blade.
I usually let the blade cool a bit in the vise before I start twisting. I've heard of people welding a handle onto the end of a pipe wrench for twisting as it gives you a two handed grip. (makes sencs, but no welder ;-( When I get twisted around so the pommel is pointing down again, I try and line everything up so its straight.
I use only spikes marked with HC on the head. These are supposedly high carbon and make better blades. I heat to red and let cool three times after forging to normalize (you've put a lot of stress in the thing with that twisting and need to "realax" it).
Then I grind, normalize three more times. Heat to non magnetic and quench in heated olive oil. Test with file to make sure you got it hard. Repeat if nessassary. Temper till dark straw color. I like to leave some black on the blade for contrast. I hand filed the ridges of the twists to flatten them out then sanded to 600 and buffed them. I ground down the head to about half its thickness as it is really butt heavy if you don't. ON this one I polished up the pommel for contrast as well. The blade is sanded to 600 grit. Thats it.
don't know if this is the best way, its just what I do. Again, twisting the handle first may be better. Sometimes when you do the blade first, the finger gaurd area will start to twist and I'd rather it didn't .
Anybody else got any tips or advice about doing these. They seem pretty popular. I was suprised at the Bill Moran hammer in show by how many people reached over my "more refined" work to check these out.....
Ed