Gary Gibson wrote: |
Can you please detail the methodology / process for slotting the hilt and (1-piece) pommel ? |
Thx Gary! I measure the tang thickness and width - trace the shape (a rectangle) with a fine sharpie on the guard. I drilled 4 holes as close as I could. Take a smaller bit that your pattern, and use a plunge attachment for it.Once you have your holes use a dremel with carbide cutters to remove the walls between the holes. Finish with the file, checking if the tang fits in regularly, you want to stay close to get the best fit possible (the best is for you to be able to hammer down the fittings). For the pommel, as shown above I've simply traced the tang on the inside, then cut guiding groves with an angle grinding cutting disk, then used these to stabilize the grinding with a grinding disk. Then I used the power file to flatten the pattern down. Once the tang was sitting in it, I closed the pommel - arc welding it. Hope that makes sense :)
Some progress. After a bit of grinding, the weld of the pommel snapped. That was expected, it's the shaping phase and I'm eating away a lot of metal on all sides and the weld along with it. Welded again, this time moving slowly along, dragging the puddle as I've seen online. Quiet a difference - getting more confident with this. There are still gaps where the two parts join, but most will go away with the final grinding on the belt, if any persist I'll fill them with weld later (same goes for the tang hole at the top, that I will narrow as much as possible for the peen). On the picture I've traced what I need to remove on one side. I'll be very close once it's done. Progressing slowly allows me to align the fittings on the tang precisely - so nothing gets misaligned. Refining the grip at the same time, planning to do it slightly angular (4 sides matching the pommel faces+ roping effect on the edges like the falstoff sword in Norwich).
Point of balance is now 10cm down the guard where it should be, total weight: 1170g, also as expected. All goes well, ETA end of next week.