My latest project sword is in. I intend to use its blade and scabbard in one project and the hilt in another. But I'm having tremendous difficulty unscrewing the round pommel nut. The seller said it was threaded, mentioned nothing about it being peened, and it doesn't look like it has been. I've tried clenching it in a pair of pliers, both with and without a wide rubber band wound around the nut, and gripping so hard my hand hurts either way, but all that's happening is the pliers are scratching the nut and the top of the pommel (after chewing through the rubber band, when I use one). Is there any other safe method I can try?

There are nut busters but what you are dealing with may be too small to use one. Basically a chisel head with a screw behind it in a cut out block. Use a dremel cut off disc and slit the nut wall (even if diagonally). Then a small chisel to spread/split it. Or, just cut it with a very sharp small chisel (make one from a screwdriver bit). Bonus points for unscrewing it with a chisel. Alternately, file two flats (opposite each other) and use a wrench or vice jaws.

Cheers
GC

Thanks! I think I'll start with the wrench method.

You could also try heating the nut.

I tried the wrench -- it worked! The nut is not looking great now, but since it's a regular old 1/4-20 it'll be no problem to reshape a new one.

Ian Hutchison wrote:

You could also try heating the nut.

Thanks for that. I'll try it next time I'm in a similar situation (which is not unlikely).