Sword handle construction advice

Thanks to everyone for their help.
I'm sorry to be confusing everyone with two projects.
I have two pieces of 3V, both 36"x2", but one is 1/4" thick and the other is 3/16".
The thinner piece is the one I'm planning to use for a katana, with no thought of welding. I think I can fit the katana design into 36".
The other project (1/4") I wish I had a longer piece, and might extend in some way.
 
Per the Crusible info welding is not recommended. It is directions for when it is necessary. I'm all for welding new and complex things but I probably wouldn't try that on something that I didn't have scrap to test the process first. That's the way welding should be done anyway.

What about going old school and doing a long tapered lap joint with solder or brake. I would still use scrap.
 
You are overthink it. Just weld a piece on with a MIG or TIG welder. Any welder with normal skills should be able to do it. It isn't a structural weld that is part of a bridge. Allow 4" of the continuous bar to be in the tang and it will be fine.
 
skillgannon said:
Per the Crusible info welding is not recommended. It is directions for when it is necessary. I'm all for welding new and complex things but I probably wouldn't try that on something that I didn't have scrap to test the process first. That's the way welding should be done anyway.

What about going old school and doing a long tapered lap joint with solder or brake. I would still use scrap.
Click to expand...

Come on ..... the world would come apart if it was not welded :) As Stacy says........It isn't a structural weld that is part of a bridge .
BW ,one guy almost win on Forged on Fire with welded blade ...he literally welded blade not tang :p:p
 
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