transcript: I've been a blacksmith armour for over thirty years. I've created weapons for over two
hundred feature films. This is Man at Arms. The Buster Sword is absolutely ridonkulous. The blade is six feet long, twelve inches wide. I'm doing a cutting edge of a steel blade with 1075 spring steel. That'll be inserted into the blade and riveted down. This is a plate of 6061 aluminum that will be plated milled out to shape here. This will all be wrapped in a band of bronze. I'll do a technique called chasing repousse. Hammering out these little squiggly lines. Just a simple little sword. I got a piece of three eighths of an inch thick 7075 aircraft aluminum. I have six feet by twelve inches. Chopped off one end of it to give a triangular tip. I brought Bill in. We call him 'William the Elder.' He's a retired foundry man machinist. I had Bill machine a slot an eighth of an inch wide by over an inch and a half deep into the side of the plate. We have a bolster or a hilt that's made out of one-inch thick aluminum. We milled a three-eighths slot three inches deep into it. Because this sword is so ridiculous it just
needs a longer handle. We have eighteen-inch long handle on this made out delrin plastic. Took a rough ingot of bronze and forged it out to the pommel and ferrule. Bronze is a little tricky. You're not supposed to forge cast ingots, but we didn't have the time to cast the pommel with lost wax casting so I'm going to take a big chunk of bronze and forge it into a ball for the pommel. And I'm going to take a smaller chunk of the ingot and forge it into the tube for the collar. That'll be used for the front of the handle. I had my assistant Brian turning the bronze ferrule and pommel on the lathe. Then I took the rough trimmed pieces to the belt grinder, trimmed them up, then used a scotch bright belt to refine them. I took the vice off the vertical milling machine and clamped the sheet of aluminum up there and used a ball endmill to mill in decorative lines on the blade. We have to heat treat a six foot length
of eighth inch thick by three inch wide 1075 steel. Grind it out a razor sharp edge. Then set that into the milled slot on the edge of the blade and rivet it down. Due to the size of the Buster Sword, I couldn't bring it over to the mill or the drill press when it was fully assembled. So we had to use a portable drill. We burned up three drills trying to hand drill through that solid block of aluminum. After we had the whole Buster Sword assembled, we hit it with the chemical to darken the aluminum to patina it to give it a dark steel appearance. I'm a pretty strong guy but just
carrying the Buster Sword out of my workshop pretty much wrecked my back and arm. The thing probably weighed seventy-five, eighty pounds. This has got to be one of the most ridiculous, huge, sword blades I've ever made. I'm pretty pleased how it came out. I don't think i want to do another one. I can mark this in my baby book that yeah, this one's done. Thanks for watching Man at Arms. Be sure
to subscribe. Tell me in the comments what weapon
you'd like to see you next.
auto_transcript: had been a blacksmith armor for over 30
years I've created weapons for over two
hundred feature films this Matadors home the Buster Sword is absolutely we don't
give us the plate is six feet long 12 inches wide doing it cutting it your play the 1075 Springfield they'll
be inserting waiting riveted to know this is a plea a 6061 aluminum that would be milled out shakespeare the
small beer after beer and a bronze brought to technique called facing
written phase yeah little with LIBOR just a simple little
sore I by got a piece 3/8 one-inch thick 70 75
aircraft at six feet by 12 inches chopped off
I'll one and if it's given the triangular
tips abrupt villain week on William the older
is a retired I found remember she knows had to bill machine a slot for me for
the next wifi up over an inch and a half eclipse is
that a outside the place we have a bolster or killed that's made
out of one-inch thick aluminum with milled the 3/8 manage slot 3 inches
deep into it this is sort is so ridiculous it just
needs a longer handle we haven't eighteen-inch more careful on those made
out of towering plastic put a rough you get a bronze forged out
to be a formal Farrell Prinsloo 3 you're not supposed to be able to
forge casting its but the we have time to care final lost wax casting so strong wats imported will fall malval gonna take a smaller truck thing yet
important as well a2 for the caller that we use the for
the heavens I had my assistant Brian turning the bronze payroll and Pall Mall on the
laser and then I took the rock turn pieces to belt grinder true them up
again use the stock rate fell you refined took the vice of the vertical milling
machine unclamps peachy the aluminum up there use the ball in bill to million decorative lines on way 302 he treat a six foot length eighth
inch thick by 3-inch wide 1075 steel grind it out you razor-sharp edge set that into the mail
slot on the after the blade and riveted due to the size of the
Buster Sword I could bring it over to the bill for
the drill press was fully assembled so we had to use a portable drill for 232 roles trying to hamper of that's all block a home after we had the
whole Buster Sword assembled we hit it with the chemical to darken
the aluminum to patina get into a dark steel parents I'm a pretty strong guy but just during
the past is stored out of my workshop pretty much wrecked
my back to normal the thing probably wait 75 pounds this is gonna be one of the most
ridiculous huge soared place I've ever made a
pretty please without came out I don't think I want to do
another 15 to I can to mark this is my baby book that yeah this
one to no paper no by thanks for watching bennett arms be sure
to subscribe tell me in the comments what weapon
you'd like to see next
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