Hi Redleg,
I know you meant no offense by your comments, but I'll admit a few of them chaff a bit. No harm no foul though, and if my response is a bit "stiff" it will at least be courteous.
To answer your questions,
YES! The MIG weld was stress relieved and annealed, I know because I stood there and watched him do the work and I have full confidence that the weld is at least as strong as the original unbroken steel was.
I have been in the past, an aircraft mechanic, industrial welder, blacksmith, and I am a well trained gunsmith. I'm qualified to know if two pieces of metal are well joined or not.
No, I do NOT engage in "stagecraft-type swordplay."
What we do is a Martial Art, ala' John Clements etc. It is not choreographed, nor are the blows offset. (We thrust "bent wrist" for safety purposes, all else is authentic technique.)
I think that most people have some rather unrealistic ideas of what a rapier (or any other sword) can stand up to over a period of severe use.
You seem surprised that a rat-tail tang will eventually break, but consider the force and sheer footpound weight of impact.
How many blows are struck in a duel?
Anywhere from one to one hundred, who knows? There is no "average" duel.
I'm convinced that 99% of the people who buy a sword never use it for more than a wall hanger, or to take out in the yard and swish through the air. (Or try to chop and oak in half with a rapier!) That's their business and I'm not disparaging them, I merely point out that these people cannot know much about how well put together their sword actually is. (The fact is, the number of people who buy a sword and actually use it as it was intended, is pretty much statistically insignificant.) If these people aren't USING their swords, obviously a rat tail tang will hold up quite well.
However, with hard and frequent use, eventually the stresses will take their toll and repairs will be required whether the blade be a CAS or Deltin.
Remember, that the surviving (period) examples we see today are not the "beaters" that were used to practice and learn with. They are instead, the "dress" or "presentation" blades that were carried as ornamentation and may have seen 5,10, 20 duels, (or none!) throughout it's actual carrying life.
I have fought more than 20 duels in one DAY with CAS and Windlass blades! The fact that these "wall hangers" last as well and as long as they do is impressive indeed, and "puts the lie" to the idea that they are "wall hangers."
I've SEEN wall hangers and would never THINK of even swinging one through the air, let alone fighting that blade. (The Marto Katanas come to mind.)
"My safety and the safety of those I train with are more important to me than saving a few bucks."
I am trying to bear in mind that you do not know me and have no way of knowing the level of my knowledge or training and so I shouldn't take offense, but I have to admit, I find your tone and your assumptions a bit offensive anyway.
The safety of my opponent is more important to me than my own. I will do nothing to risk his safety and have on MANY occasions passed up the chance of taking the point because I thought it MIGHT be a chancy manuver, and rather than take the risk, I'll pass the point.
In over two years of dueling, with as many as 90 duels taking place each week, (30 members, 3 duels each, not counting warm ups and practice!) the most serious injury we've had is a knuckle cut that required two band-aids. (Hand cuts will happen, even with gauntlets such as we always wear.)
Safety is EVERYONE'S primary concern, and honor lies in winning with the gentle touch rather than the wild slash or hack.
"To touch without being touched, to win without injury."
These are our goals and I believe that any of the more experienced members of our group could hold their own against any live steel swordsman in North America. They may not win, but they will not leave the field embarassed or humiliated.
Safety comes from control, control comes from mastery, mastery comes from training.
So in closing Redleg, first let me again apologize if you perceive any "stiffness" in my answer to you, and let me assure you that I'll get over it, you don't owe me an apology, we're on good terms.
I suppose it's much like someone going to a new Dojo for the first time, even though they may be a master, they must "show their bona fides" before anyone will take them seriously. You can't blame that master for being a bit miffed when everyone assumes he's a white belt though.
------------------
Tráceme no sin la razón, envoltura mi no sin honor
Usual Suspect