okay phew!! I thought for a minute I had chosen a design that really sucked.
Well first of all.. yeah the blade looks terrible in that picture, but believe me it is in perfect condition. I have not wiped the blade since I got it, and it still has a generous amount of oil from shipping, which has attracted a lot of dust to it.
I first started off with the pommel. At first I tried to engrave the grooves - I had in my mind to just engrave a deep groove - but the results were terrible - very uneven and "bumpy". I realized later that I had the speed settings too low - but nevertheless it was the wrong tool anyway.
Then I used a circular diamond cutter. I rested the pommel on the table and set the dremel tool in a fixed location (I have a dremel stand), and just rotated the pommel. The initial results of this again were disastrous. For some reason the dremel tool just kept sliding down making the cut uneven. I still can't figure out why! I thought that maybe I didn't secure the stand properly, but even after tightening as hard as I could the dremel tool still slided down after cutting a few seconds.
Eventually after a while the dremel tool stopped moving down, even though i didn't do anything differently. I just had to watch it carefully to make sure it didn't slide down by itself. Anyway, that's why the groove closest the grip is wider than the other groove - but thankfully I salvaged it and it actually looks like it's part of the design.
The circular cutter is very thin, but it cuts a groove about 1mm thick. So for the second groove, I had to cut two grooves side by side to make a thicker groove, and then round off the rough edges inside the groove. By this time I had the cutting down pat, and it was a very easy process to get it very precise.
As for the grooves on the cross guard, at first I tried to keep the dremel tool fixed to the stand as before but it was harder to get it precise, so I just held it by hand and cut the grooves free-hand. It was a lot easier because I only had to cut straight lines on a flat surface. One just has to close one eye and look at it from the other to ensure accuracy.
By that time the engraving of the script was a piece of cake. Of course all of these cuttings and engravings were first stenciled in with a black marker pen. You can see from the above pictures that the grooves are very precise for a free-hand job. The grooves on the pommel are even more remarkable looking. You can see some mistakes with the first groove on the pommel, but I left them in intentionally. The script is also not supposed to look perfect - it is not supposed to look like it was engraved by a machine, but it's supposed to look like it was etched in there by "ancient procedures" whatever that means.
The idea of this sword is that it is supposed to be a used war sword, not some decorative mantle piece, so it is not supposed to look pristine. Part of the charm of the original Lord of the Rings swords is that they looked ancient and used - and that's the look I was after. I noticed from the pictures of a lot of custom sword owners that owners like to have their swords looking pristine, and that's fine but they won't look like they were actually swords used on the battlefield.
Check out the original Glamdring sword from LOTR:
You can see the "used" look is intentional, and it looks fantastic. The whole fantasy thing may be corny to some, but for me it's realizing a child-hood dream. Thanks to you guys I actually HAVE a real sword, not some fake decorative sword. I like the idea of transforming a regular sword into something totally unique that is my design from scratch - it is truly *my* sword.
That gold stuff is just a permanent gold marker pen but it smudges if it comes into contact with oil. I'd like to solder some goldish metal in there but I have no idea how or what material to use that can come cheaply. Any suggestions?