I’ve been busy with a last minute project so I am a bit late posting this, but better late than never… I am going to participate in the Solingen show this year and here’s a new piece I got ready for the occasion. This is another version of the lovely Indian sosun pattah-sword design. The sword is markedly bigger than the previous sword (that is still looking for a home), but the biggest difference is the hilt that is made of cast bronze.
Here are the basic stats: oa. length 85cm, blade length 71,5 max blade width 4,2cm, blade thickness 9mm, weight 1,326kg and point of balance 12,3cm from the guard.
The T-ribbed blade is forged of 990-carbon steel and the hilt was cast by my next-door foundryman after the wax model I made. As I knew that the casting process is somewhat primitive I left out all decorative work from the wax. Also, as the weight of the hilt was likely to be excessive it was necessary to be able to work with the lines of the hilt without being hindered by cast-in decorations. The casting process went fairly well - there were only a few disturbing shuts and bubbles.
Because bronze is such heavy material it took some inspired grinding and LOTS of filing to get rid of the extra weight. The problem is that the original hilts are often so tiny that no normal-sized hand will fit in them so when the size of the grip is increased to accommodate a bigger hand the weight also grows rather radically…
The decorative work technique on the hilt was something that I had done earlier only in a much smaller scale. In my eyes it turned out ok, giving out a slightly rough outlook that just what I was trying to achieve. The “makara” on the knuckle-guard is my version of the mythical beast -clearly this one is more closely related to ducks than tigers or lions!
The blade is decorated with free-hand etchings to simulate the koftgari-decorations of the originals.
Unlike the originals in which the blade is held in place only by glue, this sword has the tang riveted to the pommel the same way I do with the European-style swords.
To complete the piece, there is an all leather scabbard for the sword, with decorated scabbard mouth and chape of the same material.
I include some pictures of the work process also - the transformation of the hilt from green wax to decorated bronze is somehow so impressive…
I hope you enjoy the pics.
JT












The wax model of the hilt sans knuckle-guard


The hilt parts cast with some pores visible


Filing (and filing) the hilt to shape