Forging a KATANA out of Rusted Iron CABLE

Fine, this Katana took me endless time to make and this was not easy to make it such perfect. A lot of Viewers asked me to make Katana so i tried to make most perfect Katana Sword that i can.

Overall Sword Length : 35 Inches
Handle Length : 8 Inches
Blade Length : 26 Inches

Some of the Processes of making this beautiful KATANA:
Forging:
It took me almost five days to prepare and hand forge Iron Cable piece into a long Metal Strip and this was one of my most complicated forging ever. I don't have any power hammers so all the forging as well as welding i did with hands and turned a cable piece into an almost 34 - 35 inches curved steel strip.
Grinding:
I make some rough grindings of curved strip on my new Belt sander and turned the strip into a well shaped steel Katana workpiece. I also hand sanded all the edges of the sword with help of flat file to remove almost all the roughness.
v. I made the blade bevel with a help of flat file.
v. The Blood Groove was made by my professional angle grinder.
v. Sanded the blade to remove roughness.
Hardness:
There is few professional ways to harden a Katana and one of them is (Insulation) Covering all the sword in Heat-Resistant clay exept blade edge. After that we heat it into the fire to critical temperature. We use water to quench only the Bevel part of the heated sword. Now the bevel is hard and remaining sword is more soft. Best way to increase Strength, Toughness and Hardness of the sword is tempering.
Habaki:
This is wedge shaped metal piece traditionally made by forging some brass or copper but also we can make it by using thick brass sheet. And it is used to support the Handle fittings below.
Handle:
Handle consists of four parts.
v. GUARD: The purpose of the guard (Tsuba) is hand protection and balancing of the sword. I made it by casting brass metal and turned into a beautiful piece which separates the handle and the sword.
v. Kashira: Kashira is a roundly turned brass piece which caps the end of the handle.
v. Spacer: This is thin little piece which fits on tang and seals all the handle parts so everything is securely fixed.
v. Wood: Any light wood covered with soft leather uses as a handle of the sword, this can be wrapped with a cotton strips.

Forging a KATANA out of Rusted Iron CABLE
#Forging
#Almostperfectrestoration

Cautions:
Always wear eye protection while working with grinders.
Always wear gloves while sanding.
Stay Focused.

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