Alrighty, I got a new project done! Wooden Swords! I made a video that I’ll link, but I’ll also give a play-by-play in stills here.
Also i’m giving away all of the CAD files for these swords so anyone can make them ( at chopbangbuzz.com )!
First the video:
Now the play by play:
First of course was designing it all up in CAD:
Once all of the design/toolpath was ready, I drilled indexing holes into the table and stock wood so that when I flipped it to machine the opposite side everything lined up perfectly:
There were two main operations, a roughing pass and a finishing pass. Here is the roughing pass using a .25 end mill:
And then a finishing pass using a .25 BALL NOSE end mill, at an 8% stepover (0.02") :
The guard was very straightforward. It’s designed to fit perfectly onto the sword body, but is also very simple:
With everything complete, you can see how tabs were used to keep everything in place for both part positions during the machining.
Of course those had to be cut free. I used a flush cut saw and a razorblade:
Then they were all sanded back with a spindle sander:
Glue was used to make sure everything stays put:
Then the dowels were added, and everything clamped together for an hour or so.
The dowels stick out afterwards, but they can be cut away with a saw.
… and then sanded flush with the rest of the sword.
Finally, some polyurethane and it’s done!
If you are interested in my projects, please consider joining my youtube channel. I’d like to try and grow it, and it’s still very small (less than 25 subscribers!). Also I have a website where all of the files are provided for free, along with lots of other designs/files for free: http://www.chopbangbuzz.com
it does get pretty deep since the stock is .75" thick to begin with…