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  • I've been a blacksmith armour

  • for over thirty years.

  • I've created weapons for over two hundred feature films. This is Man at Arms.

  • The Buster Sword is absolutely ridonkulous. The blade is six feet long,

  • twelve inches wide.

  • I'm doing a cutting edge of a steel blade

  • with 1075 spring steel.

  • That'll be inserted into the blade and riveted down.

  • This is a plate of 6061 aluminum that will be plated

  • milled out to shape here. This will all be wrapped in a band of bronze.

  • I'll do a technique called chasing repousse.

  • Hammering out these little squiggly lines. Just a simple little sword.

  • I got a piece of three eighths of an inch thick 7075 aircraft aluminum.

  • I have six feet by twelve inches. Chopped off one end of it to give a triangular tip.

  • I brought Bill in. We call him 'William the Elder.' He's a retired foundry man machinist.

  • I had Bill machine a slot an eighth of an inch wide by over an inch and a half deep

  • into the side of the plate.

  • We have a bolster or a hilt that's made out of

  • one-inch thick aluminum. We milled a three-eighths slot

  • three inches deep into it.

  • Because this sword is so ridiculous it just needs a longer handle.

  • We have eighteen-inch long handle on this made out delrin plastic.

  • Took a rough ingot of bronze and forged it out to the pommel and ferrule.

  • Bronze is a little tricky.

  • You're not supposed to forge cast ingots,

  • but we didn't have the time to cast the pommel

  • with lost wax casting

  • so I'm going to take a big chunk of bronze and forge it into a ball for the pommel.

  • And I'm going to take a smaller chunk of the ingot

  • and forge it into the tube for the collar.

  • That'll be used for the front of the handle.

  • I had my assistant Brian turning

  • the bronze ferrule and pommel on the lathe.

  • Then I took the rough trimmed pieces to the belt grinder, trimmed them up,

  • then used a scotch bright belt to refine them.

  • I took the vice off the vertical milling machine and clamped the sheet of

  • aluminum up there and used a ball endmill

  • to mill in decorative lines on the blade.

  • We have to heat treat a six foot length of eighth inch thick by three inch wide

  • 1075 steel.

  • Grind it out a razor sharp edge.

  • Then set that into the milled slot on the edge of the blade and rivet it down.

  • Due to the size of the Buster Sword, I couldn't bring it over to the mill

  • or the drill press when it was fully assembled.

  • So we had to use a portable drill.

  • We burned up three drills trying to hand

  • drill through that solid block of aluminum.

  • After we had the whole Buster Sword assembled, we hit it with the chemical to

  • darken the aluminum to patina it to give it a dark steel appearance.

  • I'm a pretty strong guy but just carrying the Buster Sword out of my

  • workshop pretty much wrecked my back and arm. The thing probably weighed

  • seventy-five, eighty pounds.

  • This has got to be one of the most ridiculous,

  • huge, sword blades I've ever made.

  • I'm pretty pleased how it came out.

  • I don't think i want to do another one.

  • I can mark this in my baby book that yeah,

  • this one's done.

  • Thanks for watching Man at Arms. Be sure to subscribe.

  • Tell me in the comments what weapon you'd like to see you next.

I've been a blacksmith armour

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