Ashokan Sword pictorial

[Delbert Ealy]

So I go every year to The Ashokan seminar, and for the last couple of years we have had an unofficial challenge to make an item and show it off. This year I challenged my fellow attendies to make a sword. Well its getting close so I decided to start working on it, and I'm showing the steps here.
I had some leftovers from some other damascus projects that I combined to make the billet.
I used 9 bars 3/4" square and 6" long.
http://KnifeDogs.com/gallery/files/1/2/billet1.jpg
http://KnifeDogs.com/gallery/files/1/2/billet2.jpg
The billet with handle in the forge.
http://KnifeDogs.com/gallery/files/1/2/billet_in_forge.jpg
The billet after 3 heats, it is solid and drawn out a bit.
http://KnifeDogs.com/gallery/files/1/2/billet4.jpg
This is ater an hour of forging, I took my time a bit because of the construction. The drawn out end is an inch square. The billet now is about 27 inches long.
http://KnifeDogs.com/gallery/files/1/2/billet5.jpg
A pic of my press.
http://KnifeDogs.com/gallery/files/1/2/press.jpg

[Jeff Pearce]

Very cool I will be watching this build. thank's

[Delbert Ealy]

I'll be posting some more tomorrow, I have a couple hours in the morning to work.
Del

[LR Harner]

too cool cant wait to see the work and thenthe finished blade in NY

[stabber]

Del,You'll be at Ashokan this weekend?:eek:

[Josh Dabney]

Delbert,
Very cool thread 2thumbs We're all gonna enjoy watching your progress on this.

-Josh

[Delbert Ealy]

Del,You'll be at Ashokan this weekend?:eek:

Yeah, I'm one of the demonstrators this year!
Oh by the way its next weekend.
Are you going?

[Delbert Ealy]

too cool cant wait to see the work and thenthe finished blade in NY

I'm cutting it close to finish in time, but I can work under pressure, and I can work fast.

It will be good to meet you as well, Rob talks about you all the time.

[BossDog]

Del, I am really looking forward to watching you do this one.
more pics=better

what steels are in that damascus is that?
t

[Delbert Ealy]

Del, I am really looking forward to watching you do this one.
more pics=better

what steels are in that damascus is that?
t

The steels are O-1,L-6 and pure nickel.
I will keep the camera handy at all times. One problem I have had in the past when taking progress pics is that I work so fast I forget to take pics in between steps. One thing that will slow me down with this one is I will need to build a new quench tank.
Thanks Boss

[LR Harner]

only thing i make fast in the shop are mistakes
jsut work it will get done

im sure deker speekes highly of me :)
"get this harner wants to try (insert messess up steel plan ) he will never learn"
:)


I'm cutting it close to finish in time, but I can work under pressure, and I can work fast.

It will be good to meet you as well, Rob talks about you all the time.

[Delbert Ealy]

So, I cut off 13 inches from the billet I welded together yesterday and started twisting it. To make it more interesting I am doing a reverse twist, which means that I twist a little bit one way and then a little bit the other way. Back and forth up the bar until I do the whole thing. By the way, whenever I use the word interesting, you can substitute the word difficult.
http://KnifeDogs.com/gallery/files/1/2/bar1.jpg
after the second twist, in the vise
http://KnifeDogs.com/gallery/files/1/2/bar2.jpg
Me twisting the third twist
http://KnifeDogs.com/gallery/files/1/2/bar3.jpg
after the third twist
http://KnifeDogs.com/gallery/files/1/2/bar4.jpg
Me twisting again
http://KnifeDogs.com/gallery/files/1/2/bar5.jpg
The last twist is done
http://KnifeDogs.com/gallery/files/1/2/bar6.jpg
I start to glatten out the bar
http://KnifeDogs.com/gallery/files/1/2/bar7.jpg
http://KnifeDogs.com/gallery/files/1/2/bar8.jpg
http://KnifeDogs.com/gallery/files/1/2/bar9.jpg
http://KnifeDogs.com/gallery/files/1/2/bar10.jpg

[Delbert Ealy]

The bar flattened out and ready to start forging the point
http://KnifeDogs.com/gallery/files/1/2/blade1.jpg
After the first heat on the point
http://KnifeDogs.com/gallery/files/1/2/blade2.jpg
http://KnifeDogs.com/gallery/files/1/2/blade3.jpg
http://KnifeDogs.com/gallery/files/1/2/blade4.jpg
http://KnifeDogs.com/gallery/files/1/2/blade5.jpg
Nice and pointy, each pic above was taken after a single heat
http://KnifeDogs.com/gallery/files/1/2/blade6.jpg

[Delbert Ealy]

Forging out the tang, like above each pic is after a single heat.
http://KnifeDogs.com/gallery/files/1/2/tang1.jpg
http://KnifeDogs.com/gallery/files/1/2/tang2.jpg
http://KnifeDogs.com/gallery/files/1/2/tang3.jpg
http://KnifeDogs.com/gallery/files/1/2/tang4.jpg
http://KnifeDogs.com/gallery/files/1/2/tang5.jpg
http://KnifeDogs.com/gallery/files/1/2/tang6.jpg

At this point the blade is 24" long overall and 1 1/2" wide. This is the point where I had to quit for now, the wife went to work and left me with the little one.
http://KnifeDogs.com/gallery/files/1/2/lilly1.jpg
I am about ready to forge in the bevels. I worked on this for 2 1/2 hours and I could have done it in half that time without taking pics, but its worth it.
More later or tomorrow

[John Barker]

This thread is so cool! Thanks for posting it.
-John

[stabber]

9/26&27? May not be able to. But If I can change something around then Yes!! I'm really looking forward to it!!2thumbs
Yeah, I'm one of the demonstrators this year!
Oh by the way its next weekend.
Are you going?

[deker]

9/26&27? May not be able to. But If I can change something around then Yes!! I'm really looking forward to it!!2thumbs

It's the 18-20th Stabber...just so you know.

-d

[stabber]

Thanks Deker2thumbs

[Delbert Ealy]

After drawing the blade out a bit, it is ready for bevels
http://KnifeDogs.com/gallery/files/1/2/bevels1.jpg
Beginning to forge in the bevels, I will work my way up the blade to the tip.
http://KnifeDogs.com/gallery/files/1/2/bevels2.jpg
http://KnifeDogs.com/gallery/files/1/2/bevels3.jpg
http://KnifeDogs.com/gallery/files/1/2/bevels4.jpg
http://KnifeDogs.com/gallery/files/1/2/bevels5.jpg
After just 5 heats the bevels are forged in and now it goes to grinding.
http://KnifeDogs.com/gallery/files/1/2/bevels6.jpg

[David Wesner]

This is the point where I had to quit for now, the wife went to work and left me with the little one.
http://KnifeDogs.com/gallery/files/1/2/lilly1.jpg


Best pick of the lot .......................... 2thumbs 2thumbs

Don't get me wrong, I LOVE knives, especially big ones, but pics of the little one in this kind of shape are priceless !



Nice work on the Sword Del ! Real nice ;)

What is the end plan ? Gladius ?


& thanks for taking the time to show your work. Very much appreciated !!


:cool:

[BossDog]

lets see the press you are using please...I love tools.

[Delbert Ealy]

lets see the press you are using please...I love tools.

The 6th picture on the first page Boss.

[Delbert Ealy]

So, I started in on the grinding and got wrapped up in it and forgot to take as many pics, this first one is after about 20 min grinding.
http://KnifeDogs.com/gallery/files/1/2/g1.jpg
The same stage of grinding, but I swabbed it with ferric chloride so you can see the pattern.
http://KnifeDogs.com/gallery/files/1/2/g2.jpg
Closer view, even though its a little fuzzy.
http://KnifeDogs.com/gallery/files/1/2/g3.jpg
A little further along.
http://KnifeDogs.com/gallery/files/1/2/g4.jpg
Finished grinding.
http://KnifeDogs.com/gallery/files/1/2/g5.jpg
Etched.
http://KnifeDogs.com/gallery/files/1/2/g6.jpg
Starting on the hand sanding of the blade, worked on this for an hour and a half last night and this stage is done too.
http://KnifeDogs.com/gallery/files/1/2/g7.jpg

Next up is the assembly of the guard, handle and pommel.
I'll try to get more pics of this stage.

[RAGUEL3]

Lookin terrific, all that hammer work, sheesh,.. thats WANTING to put the maximum of yourself into it.

[David Wesner]

Very nice work Del 2thumbs

Looking forward to the next steps.

This is going to be a BAD ASS BLADE !!!



:cool:

[JAWilliams]

That is great. Like the pattern.

[David Wesner]

Hey Del :)

You may still be on the road home from Ashokan but what the heck, I'll ask anyways.

Were you able to finish the sword before leaving ?

I'm just dying to see some finished pics unsure

Hint Hint ;)



:D

[Delbert Ealy]

I was able to finish the sword, the morning I left. I'll get some pics up in a little while.

[RAGUEL3]

Cool, love to see how she turned out.

[bubba-san]

very nice work , got my blood going for sure ! haven't made a sword in a while . I see a wakizashi in the horizon somewhere ?? like the press too ......... Bubba

[Chris Martin]

I am loving every step of this beauty in progress. Looking great Del.

Next stage please2thumbs

C

[Delbert Ealy]

http://KnifeDogs.com/gallery/files/1/2/fittings.jpg

http://KnifeDogs.com/gallery/files/1/2/sword1.jpg

http://KnifeDogs.com/gallery/files/1/2/sword2.jpg

http://KnifeDogs.com/gallery/files/1/2/sword.jpg

[T Blade]

Del,

That is a sweet looking Gladius yea!

That's the one you are going to bring to Ashokan Sword in 2010, right? Can't wait to see it.

I've got to get started on my project for the Sword event :)

[acmetsala]

I was really cool to see you make this sword. It looked great.

[Rock]

Next up is the assembly of the guard, handle and pommel.
I'll try to get more pics of this stage.

Delbert, just stumbled across this thread. I love Gladiuses and this is a great looking one! Can you tell us more about the handle and if you made a sheath?

Thanks!