Fellblade: Step by Step – Part 2

Read Part 1: Designing the Fellbladehere

I got the steel blanks cut out on the CNC Plasma table at work. I’m using 3/16″ carbon steel plate for the main blade, and 3/8″ for the hilt collar and the handle. I got the 3/16″ plate sand-blasted so that I could texture it properly and sand it for the desired effects.

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I printed out 1:1 scaled drawings of my CAD files, and traced the shape of the edge with a sharpie, then I spent a few hours grinding down the edge by hand with an angle grinder, belt grinder, dynafile and pneumatic sander. This is a pretty brutish, crude blade, so I didn’t really need to take my time. After the edge, I sanded the flat surfaces and then I ground the details on the end of the handle. Welding on the hilt collar and handle was next.

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To get the onyx-like surface, I started by sanding it with patches, lines, and grids. After taping up the edge, I used a rim tint on the surface. I did a second coat 20 minutes later, then took off the tape and hit the whole blade with a clear coat.

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The handle is oak half-round with the back milled out. I painted the halves black and stuck them on with an epoxy.

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Final step was to wrap the leather handle. I did one spiral over the length, then a small collar on the bottom, and a thicker build-up at the top, near the collar.

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Enjoy the rest of the photos!

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