I make swords and other pointy things for gifts. Of course, that also means I need to practice, and try the swords out, and learn new tricks . . . It's easier to justify the 100+ hours in the garage making a horrible din, that to justify the 500+ dollars for a mostly functional sword.
I agree fully!!
There is hardly anything (a few, but not many) more satisfying than making or being involved in making a good sword or blade - be it purely functional or beautiful and decorative.
I was lucky to work as an apprentice blacksmith for about 4 years to put myself through university and while the boss mainly did industrial work (ie train/truck components etc) to pay the bills, he had a sideline in weapons and iron work. I still have my first damascus blade from that forge, many knives and a couple of swords.
My katana is purchased but it would be great sometime to experiment with traditional Japanese tempering techniques if possible; we used to mainly temper and harden blades with baths of industrial oil in varying temperatures.
I don't have access to or room for a forge set-up now but do miss those times immensley. With that background it really makes you appreciate all the more a well crafted weapon - I recently got back from Japan and going through the Tokyo sword museum and other displays through the country was mouth-watering and an incredible humbling, almost 'spiritual' experience at times.
Of interest, what kind of set-up do you have at home (in the garage I'm assuming?? - no wife could be as accomodating as having that in the house??). Do you have a mini furnace or forge and an anvil and how do you cool/quench the blades - cold/warm water - or do you use oil or clay? And then for tempering do you just use the home oven or again, something in the garage?
Apologies for the q's but my mind is ticking over now on maybe another use for our own garage...
I use a propane forge in the backyard, and I started out with an A.S.O (Anvil-shaped object) from Harbor freight. I get leaf-springs for free from a friend who has a trailer repair place. He lets me dig through his scrap every once in a while. When I lived in the country I had a coal forge, and I miss that a lot. Other than that, my main tools are a cutting torch and 4.5" angle grinder with sanding wheels.
I don't have enough heat to forge-weld, so I'm not going to try any damascus work anytime soon, but I am getting one of those car-port thingies for Christmas, and I got a nice 150 lb anvil last summer. After the new year, that's going to be my new "shop." I'm really fortunate that my neighbors right next to the shop are big fans of my work, and they don't mind the noise at all, as long as I'm respectful about it. The husband is deaf, and just turns off his hearing aids (he's a DIY'er, too), and the wife actually likes the sound of the forge. Go figure.
I usually cut the shape with the torch, forge the curves and straighten the blade, then grind into the final shape. Polishing usually takes as long as the forging/shaping process.
I usually work in the winter, so I "air quench" the blades. Then I temper them by careful timing of the grinder. I usually grind until the metal gets to that nice purple, then back off, and let that area air quench as well. It gives the blades a springier temper, which I like, since I usually don't go for razor sharp/"stupid sharp" for the swords. For the smaller stuff, like knives, I get a few gallons of old airplane motor oil every once in a while, and that gives a nice, slow quench with a high flash point.
The furniture is a whole different story.