I was wondering if I could poll the various sword makers on to how they start a piece. I realize everyone does it differently, but I guess my question is, where do you begin? Do you have a thick sheet of steel and then use like a plasma cutter to cut out the shape, and grind from there? Do you melt down ingots and pour it? Can you even purchase high-carbon steel or do you need to do preliminary purification? I'm just curious as to which method is preferred and why.

Thanks!

Lots of different ways. I think most makers use mill-run carbon steel, although there are those who actually make their own steel and they get my respect for the effort. I believe Tinker uses a bandsaw to profile the blade shape from mill run steel.
Angus Trim uses machining equipment to cut the rough bevels, fullers, and profile, and this method is used by a few others.
Smiths have the option of shaping by hammer, or dies in a power hammer, etc.
Some just start grinding...and keep grinding....

Read this myArmoury.com feature article:

http://www.myArmoury.com/feature_groundpound.html

when i start a piece I usually purchase or find (legally of course) a good sixed piece of high carbon steel. almost every piece of rebar is very high carbon so look at junk yards or construction sites. so take the rod and just start pounding it to shape. I will forget the shape, forge in somewhat of the edge in and then grind it all, heat treat and temper (still working on the recipie though) and then sharpen hone and polish.

junkyards and construction sites are your freinds...

Aaron

Except for pattern welded pieces, we usually start with an old cutting chisel from a turning tool. Since I am not sure about the things name in English I'll just add a (bad) picture. ;)

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Bad lighting, bad camera ...
Many things might ruin a picture! [ Download ]