Ohio University - 2019

Starting with a reference image, I drew out a full-scale image of the sword hilt and cut 1/2” rod to length for the quillons. I milled the taper onto the quillons with the drill press and a series of grinders and sanders and shaped the detail at the ends with a series of hand files. The headlock was assembled and tacked in place on the blade and then removed to finish welding without damaging the blade, then cleaned and shaped with a grinder and Dremel tool before getting the quillons tacked on and blend-welded. I then used the same techniques to taper and shape the knucklebow before bending it using the oxy-acetylene torch. I then welded the bow on and cleaned the welds to create a smooth joint. I used wire to estimate the lengths of each of the six rings before cutting them out of 1⁄2” and 3/8” rod before milling the taper in the same method as the quillons, ensuring they were even with my calipers. I then drew in the detail and shaped each by hand with a series of hand files before cleaning with sandpaper and a wire brush. Two by two I bent the pieces using an oxy-acetylene torch an tacked them in place to the rest of the guard. When everything is finally perfect, they are fully welded and then blended smooth with grinders, sanders, files and polish. Finally I turned a grip of rock maple before drawing and filing in the spirals by hand and wrapping the piece in black leather and silver braided wire. The final product is completely stage combat-worthy and actor-safe as well as accurate to the original reference.