Introduction: Turning a Old WRENCH Into a SWORD
I turn an old rusty wrench into a sword. I didn't #forge this because I couldn't get the thick metal hot enough with my MAP gas, so I ended up doing the entire thing using my Supraone angle grinder tool. I did a lot of #woodworking on the handle using walnut and white oak inlays. This was a fun build, I love transforming old tools into completely different things.
Step 1: Find Old Wrench.
I had this old wrench for a long time and have never used it so I decided to turn it into something more useful.
Step 2: Cut Off Ends and Grind Down Raised Metal
Using an angle grinder with a cut off disc, I cut both ends off. This particular wrench has a raised surface of metal which I changed out to my flap disc to grind down flush.
Step 3: Cut Out Sword Shape and Bevel Both Ends
I cut out the sword shape using my cut off disc, then switched back to the flap disc to grind down the edges on all sides. This took a lot of grinding. Be sure to put a line right down the middle so you don't grind too far on one side.
Step 4: File and Fuller
Parts of the sword which you cannot reach with the angle grinder will have to be filed down. I used various files to file down the tang of the sword. I also used a large flat file to refine the cutting edges of the sword. Next I used my angle grinder with the cut off disc to create a straight line down the middle of both sides of the sword. This will be my fuller.
Step 5: Shape Fuller, Sand, Polish
To shape the fuller I used a small dowel (it was a skewer stick) and sanded by hand the fuller until it was nice and smooth. I then hand sanded up to 1500 grit. I then brought it to the buffing wheel and polished it out.
Step 6: Handle
I wanted to do a fully wood handle. I used walnut and white oak to create the handle and guard portion of the sword. I first did a glue up inlay of both pieces (see pictures). Once the glue was dry I took it over to my belt sander to get all the sides perfectly square.
Step 7: Sharpen the Sword
Using a whetstone I sharpened the sword up to 6000 grit making it super sharp. It is crucial to do this before you attach the handle.
Step 8: Shape the Handle, Glue Up
I used my belt sander and rotary tool to shape the handle.I then did a TON of hand sanding before gluing everything up. I glued everything up using 5 minute epoxy.
