My first attempt at a Pas de Armes sword...

Cailin · Post by **Cailin** » Thu Feb 04, 2010 1:36 pm

So, with apologies to everyone who has done this better...

Started off with a 2' thick piece of rattan. I don't have alot of tools, so I split it with a chisel, and then hammered a machete down the sides to split off about a quarter inch off either side, leaving me two flat side and about 2' by 1.5 inch and 40 ' long. Then I used a plane to shave it down to 1.25 inches at the tip, and about 1.5 or so by the cross guard.

I wanted to try something I hadn't seen before, so I used a router to put a fuller in the 'blade'.

Here's the blade marked for the fuller.

Gryffinclaw · Post by **Gryffinclaw** » Thu Feb 04, 2010 1:40 pm

have any pics?

Cailin · Post by **Cailin** » Thu Feb 04, 2010 1:44 pm

Yeah, first time I've uploaded images here. Figuring out the particulars. more to come...

Cailin · Post by **Cailin** » Thu Feb 04, 2010 1:48 pm

Here's how the fullering came out. I got the router for 20 bucks off of craigslist... first time I've ever used one. Practiced a bit on a chunk of pine board before trying this. Next time I'll try to rig some sort of guide.

Cailin · Post by **Cailin** » Thu Feb 04, 2010 1:50 pm

After that, I used the same method I did to shape the flat of the blade, using a chisel and machete to rough out the profile. Then I used the plane to fine tune the shape.

Cailin · Post by **Cailin** » Thu Feb 04, 2010 1:52 pm

I shaped the hilt by cutting a couple of notches with the jigsaw, then using the chisel to knock out a large chunk of material on both sides. Then, I shaped it using the cross guard as a guide, and just shaved it with a knife.

Cailin · Post by **Cailin** » Thu Feb 04, 2010 1:55 pm

I thought about putting the cross guard on next, but decided after looking at the situation to go ahead and tape the sword so the ends could be finshed nicely.

I used strapping tape , around the top, then set into the fuller, plus a couple of layers on the two edges. I should note that the edges were hand beveled so they aren't a flat edge. Next, I ran a line of black tape for the contrasting edge color. I usually use athletic tape for swords because its lighter, but this blade is already amazingly light, so I went with duct tape.

I got the idea for the black visual effects tape at the top from the Atzingers.

Cailin · Post by **Cailin** » Thu Feb 04, 2010 1:57 pm

And finally, attached the cross guard, tapped up the hilt, and attached the pommel.

Lessons learned:
-longer hilt, by about half an inch.
-smaller bit for the router.
-More practice with the router
-Find a way to use a guide with the router maybe.
-Thrusting tip.
- Better measurements all around, try to make the sword as true as possible. I think the hilt is just a tiny bit off center.

lochinvar76 · Post by **lochinvar76** » Thu Feb 04, 2010 2:07 pm

A router bench and custom guides would definately be a way to go if you want the fuller to have a more uniform and clean look. Might be more than someone wants to spend on a hobby unless you're looking to make many more of these or delve into other woodworking projects that make it viable.

Or as a labor of love, a good set of woodworking chisels could do the job. A bit time consuming but you get a very deep satisfaction when it's done.

All in all, that's a very nice looking weapon. Great work!

deflagratio · Post by **deflagratio** » Thu Feb 04, 2010 2:50 pm

Looks great. How is the handling? Have you hit anything with it to see if the fuller has structurally weakened the rattan.

Cailin · Post by **Cailin** » Thu Feb 04, 2010 5:21 pm

It feels very balanced. nice and whippy. I'm almost certain the fuller has weakened the rattan, but I don't have any imperical evidence to that effect yet. I'll probably go with Oakeshott Type XIIIb for the next one...