JC week 10 : Sword handle wooden core and first attempt paper blade

NB: journal entry for the Jewellery and Small object module at South bank Griffith university (QCA) to view the full journal click here

This post covers the creation of the wooden core (25cm long 4cm wide 2cm deep)  for the sword handle. The shape and design has been based on the feder german longsword. The intention is to create a wooden core which allows the steel rod of the sword blade and the brass tube segments. Using a length of pine timber  ( 50cm x 4cm x 2cm ) to create the wooden core.

 (BELOW : left) to be fitted 

Equipment used: Utility knife, round wood file, coarse sand paper.

ABOVE: using a vice to hold the timber in place the wooden core has been marked out , at 30cms to allow for overcuts and basic shapping of the timber has begun. 

Step 1: using the utility knife wittle away the basic shape

Step 2: using the wood file refine the shape until the brass tube segments can be inserted with the wooden core.

Step 3. Using the sandpaper, smooth the surface of the wooden core.

ABOVE: To test the fit of the brass segments, the wooden core needed to be stood upright. The fit needs to be fairly tight.

ABOVE: Finally a  horizontal channel (2mm wide ) was cut into one end for the cross guard to be inserted.  

Paper blade test

paper blade : talks about the spiritual connection, non litteral, its not a weapon for physical battle but one for spiritual battles . The blade will be made out of scriptures relating to core beliefs which have importants to me. This test is made out of regular photocopy paper

concept drawing of mold making process and final blade result

 A plaster mold is made of a sword blade.

Step 1: create a mound of sand (90cm x 15cm)  that is slightly larger than the sword blade (80cm x 5cm)

Step 2: Lay the blade down in the sand making sure that half of the blade is submerged in the sand
Step 3. Cover the blade and the sand in cling wrap, otherwise the paster will be filled with sand
Step 4. Cover the exposed blade and 2cm past its edge with 4 layers of 'plaster of paris' bandage wraps.(BELOW)

 Step 5. Once the plaster dries ( over night) gently remove the blade from the plaster of paris and brush away any sand that may have gotten into the mold. The mold is now ready.

Making the blade

Preperation:

Prepare Bond Crete 1:5 water ratio into a small bucket. For a full size blade about 1 liter of mixed bond crete will need to be used. 

Tear apporx 40 sheets of A4 paper length wise into 1 inch strips (1 inch x 29.5cm) 

Step 1: layer the mold with 4 layers of the paper strips that have been soaked in bond crete (soak for 10mins) 

Step 2: allow to dry overnight

Step 3: remove from mold (BELOW) this has now created half of the blade. 

Step 4: repeat steps 1 to 3 to create the other half of the blade

You now have two half shells of the blade, A threaded steel rod will need to be placed in one half of the mold. Along the length of the steel rod thread on 2 bolts, these will hold the blade in place. Put one bolt two inches approx. at thickest part of the blade where it connects to the cross guard. ( BELOW)

Image 1

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Image 2

 Now cover over the entire threaded steel with two layers of paper.(BELOW) and allow to try (over night).
Once dry then twist lengths of paper ( 1inch by 29.5cm) and place them into the blade cavity, filling it level with the edge of the mold. While still wet, Place the top of the blade into the mold, closing the surface and applying gentle pressure so that the blade top bonds with the filled base.

ABOVE: again allow it to dry overnight, there will be a few tags hanging off the joined edges but these can be cleaned off with a utility knife, The finished blade is very hard due to the density of the paper and is more than strong enough for the final project.