The tip of the core is ground to shape and the edge is wrapped around the core.
The edge is held on with clips. This allows it to move ( expand ) while it is being forge welded to the core.
Pattern Welded Viking Sword
I have been working on this project for about three
years now.The forge work is so intense that after a couple of week of forging
I've had to set it aside for a while and then come back to it. This is my
third sword and the largest and most involved yet.
The sword is made up of two ferrous metals C5160 and Wrought Iron. Before
the wrought iron could be used it had to be refined by hand to make it useable
( it had to be forge welded over and over on itself)
Then four bars were forge welded up. Each billet with nine layers then drawn
out to 9/16th square by 36" long
These bars were then twisted in opposite direction (two each)
All this took several weeks!
Next these four bars were stacked one on top of the other and forge welded
together the 36" length. (No small task)
This would make up the core of the sword. The back and forth stacking of the twist should give it a herringbone pattern!
Now an edge
had to be made for the sword.
The edge would have to be one piece of damascus which would run down one side, wrap around the tip and come back up the other side.
To do this I had to make 5 bars of 65 layer Damascus and forge weld them end
to end to make a finished bar 9/16th" square 6ft long!!!!!
Here is where we pick up the project with pictures..
The tip of the core is ground to shape and the edge is wrapped around the core. The edge is held on with clips. This allows it to move ( expand ) while it is being forge welded to the core. |
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Here we do what is called a "Jump"
weld. This is the hardest and trickiest part of the whole job. Welding the tip! There is two years of work to this point and if this doesn't go perfect it will all be lost and it would take another two years to get back to this point!! |
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The tip is welded on successfully
and I start working my way welding up the edge. Some work can be done on the power hammer but VERRY Carefully !! |
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Once I get the edge welded all the way
to the other end and true everything up, then begins the long job of grinding down the sword blade. I also have to make the damascus for the handle hardware. |
As always Click on pictures to enlarge.