Lord of the Rings inspired Letter Opener

Lord of the Rings inspired Letter Opener

Lord of the Rings inspired Letter Opener

Finished piece first.

A letter opener I made inspired by the Lord of the Rings High Elven Warrior Sword. This is nowhere near an exact duplicate of the Elven sword. This is my first time making something that resembles a knife, since this is just a letter opener it was not heat treated. This was more of an exercise to get an idea of what it would be like to grind and bevel a blade.

For those who prefer moving pictures:
www.youtube.com/watch?v=yIaWqAjN4Xs

First I printed out an image that I could use to make the template. I cut it out and taped it to a piece of mild steel, this is the stuff you can find at Home Depot or Lowes or Ace Hardware.
This mild steel flat bar measures 2 inches wide by 1/8 thick.
I taped on the paper template and traced the shape on to the flat bar steel.
I later realized that I should have used a finer tipped marker for this step it would have made for a more accurate tracing. The regular marker leaves a wide tracing which isn't as accurate when it comes to refining the shape so I had to remember to grind and shape to the inside of the traced line.
Next I clamped down the steel and using an angle grinder with a cutoff wheel I removed most of the excess material to get the basic shape of the blade.
More rough cutting.
Rough cut done.
This is not an ideal sander for this but I used what I had, I soon abandoned this for a 1×30 belt sander.
Next using the angle grinder with a grinding disc I cleaned up the edge and the shape of the blade.
I also used a file to refine the shape.
I also used a flap disc on the angle grinder to refine the shape.
This was the bevel shape I was trying to achieve.
This was the bevel shape I was trying to achieve.
Now it was just a matter of using the1x30 belt sander to shape the bevels I was going after. Through out this whole process I only had access to 80 and 120 grit belts so that is all I used. I would start with the 80 grit and then switch to the 120 grit to clean up an big scratches left from the 80 grit.
This was my first time doing this and I realize I still have a lot to learn and would probably do well to get a variety of sanding belts.
Once I was done with the belt sander I used the files to further refine and shape the bevels. Or at least attempted too.
After file work. After this I used sandpaper to try and clean up the blade. I started at 15 grit and worked my way up to 600 grit. Then polished with "Never Dull" product.
Next I used a piece of mesquite wood flooring to make the handles for the letter opener. I found a scrap piece that I could split in half with table saw.
Then traced the blade's handle shape on to the two pieces of wood.
I used my scroll saw to cut out the shape, I made sure to make the wood pieces larger than I needed them so I could shape them on the belt sander later.
I also shaped the bolster portion of the wood handle as this is more difficult to do once the handles are attached to the blade.
I cut the head off of a nail so I could use it as the pins for the handles.
I centered punched the blade handle for the two pins that I would need to drill holes for.
I used my drill press to make the two holes.
Quick mock up.
Before attaching the wood to the blade I made sure to finish any shaping on the blade as well as any polishing or sanding. Then using some epoxy I attached the wood handles with the nail pins to the blade.
Everything got a nice coat of epoxy.
I secured everything with clamps. I let it dry overnight.
I used a hacksaw to cut off the portion of the pins that stuck out.
Next I used my 1×30 belt sander to shape the handle.
More shaping.
The next few pics shows the various files I used to shape the handle.
I also used sandpaper to make it nice and smooth.
Finished shaping the handle.
After completing the shaping and the final sanding of the wood handle I used a dark walnut Danish tung oil to finish the wood. I applied 5 coats to the wood. I also did any final polishing to the blade.
Finished piece. I made a little stand for it out of the same mesquite wood flooring as a display. Thank you for reading all this and I hope you enjoyed this as much as I enjoyed making this letter opener.
Source : danthemakerman from Reddit