Putting a Fuller in a Blade

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Jul 8, 2002
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Hey all, I am making a Viking style dagger (maybe short sword) for a potential sale. It is going to be sort of a mini Sutton Hoo deal but with four bars instead of 8. I have the core done and I am getting ready to fab up the straight laminate edging.

Right now the core is about .5 thick, .75 wide, and 12 inches long. It is looking pretty good so far. The final width after the edging and forging to shape will be 1.25 to 1.5 and the blade will be 3/16 to 1/4 thick.

My question is this:

The customer would like a fuller in the blade, and asked if I could grind it in instead of forge it in to reveal more of the patterning. I have never done a fuller either way.

How wide and how deep should it be?
What is the best way to grind it in?
Should i just use a ball end cutter in my mill?

Thanks for your help.
 
Sean, I have used the 1/2" ball end mill method with great results. It is precise, centered and crisp edges. The 48" double edged sword took time but came out good. Should have taken pics.

If I were to press them in Id make a fixture of some sort.
 
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