All...

For details on this swords construction - please see:

http://www.sword-forum.com/viewtopic.php?f=18...p;p=277754

I'm taking the highly unusual step of posting a construction alert for the NEW Model of the DSA Longford. NONE of this applies to the OLD model of the DSA Longford which appears to use a totally different blade.

Pertinent data: upon teardown, I discovered a significantly thin tang area, about 1"-2" behind the guard. The data indicates that this area has a thickness of about 0.109 US inches :

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Observation of photo 3 may imply that the low tang thickness in this area is due to the long extension of the fuller into the grip area.

I will not be building up a sword with this blade. I'm labeling this as a CONSTRUCTION Alert rather than a SAFETY Alert, as I have no DATA regarding any actual SAFETY issues that MIGHT arise from construction of this nature.

I will add - based on teardowns of MANY DSA models - this issue is completely UN TYPICAL of any other model I have observed. I present the data, dearly hoping to avoid any over generalizations.

I wonder if that sword of yours has been completed by now, Dean.

Well? Given those measurements - no. I can not, in good conscience, re- assemble a blade that I believe to be a hazard to whoever owns it :(. I'm stuck on this one.... I could re-assemble and sell it as a wall hanger - but I worry that someone may actually try to USE this, as a sword :(.

So.... in all likelihood? Both for my good, and that of anyone else - I'm very likely going to cut the blade up, and toss it in the trash. I don't think I could live with the thought of someone getting hurt with this item.

Rather than cut it up and trash it, cut down the shoulders and make it a shorter sword with a new tang. As long as you're careful and go slow as to not affect the heat treat, it should be fine.

You can even drill guide points on either side of the fuller where you want the new tang to start so that you have the proper radius cut at the shoulder.

Just my 2 shillings.

See you at the Pony, muindor. ;)

Let's consider moving the shoulders forward, creating a shorter blade, for a moment....

I've considered doing so. The only issue? The problem does not vanish: It just gets moved BACK to a (hopefully) less critical location. I MIGHT be able to move the issue to rear by as much as 3-4 inches.

The dagger conversion - this is hilarious, as it was my first thought. But then, I MIC'd the blade, about a foot back from the tip :(. And now I can say how good distal Taper can destroy you :). By the time you get to this area? Muindor (dear brothers).... there is very little left in the way of "beef" to support a decent dagger tang :).

I could do SOMETHING - but really, I'm now in comparative economics land for a BARE BLADE. With the price of a very GOOD HT bare blade in the $100 range at KOA? No. I'm not investing the labor. I will destroy this blade. I could make it into a wall hanger - but then someone might hurt themselves with it - I can not do that.

Or you could cut off the tang and sell the blade as-is in the marketplace to recoup a little of the initial investment.

As long as you remove the worrisome area and inform the buyer you can sell it in good conscience.

Just a thought. I hate to see something go to waste, especially when you paid for it. :)