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(128 votes) Published: Dec 03, 2007 6:00 p.m. In 11 Favorites Lists Viewed 1154 times
This guide will show you how to make a Mechanical Sword, or Mecha Sword. Or at least that’s what I call it because it reminds me of those huge anime robots. I used a metal sign we had in storage, I suggest you use something close to the same material and the same thickness. If you choose to cut down a sign remember there’s a fine if you get caught. But if you do make sure it’s not something important like a stop sign or a speed limit sign. You will also need some power tool skills and know how to use a grinder and a file to sharpen the sword. This sword can get very sharp but it is also fairly heavy. It’s more for looks but is very durable and fun to play with.
Materials
- Metal
- Metal Shears (hacksaw)
- Drill with Drill Bit
- Socket Wrench (adjustable wrench or pliers)
- Tape Measurer
- Sharpie
- Nuts, Bolts, and Washers
- Spray Paint (optional)
And you will also need one of these.
Now get your Tape Measurer and Marker.
And find the image you want in your metal. Yours should look somewhat like mine but it can be slightly different. Also, I made mine one-handed, I suggest you make yours two.
Now if you want yours straight measure from those two lines. It should be the same length from tip to base.
And remember, if you mess up you can erase it with Rubbing Alcohol.
Now get your metal and place it on something very sturdy. Make sure it won’t move, if you have a friend their have them hold it. Then start cutting...
If your edge looks a little wavy then clean it up some.
That looks a little better.
Now if it’s still a little bit jagged or wavy clean it up with the grinder. If you don’t know how to sue one I suggest you look up a guide before you attempt it. Don’t hold it in one place for more than two seconds and don’t let it get to hot or it can take the temper out.
If you have a sharp edge on your handle I suggest you clean it up some too.
You have the main frame done. Great Job!
Now place that over your other metal and outline it.
Now make a line about 3/4 the width of the main frame.
Now do place that over another piece of metal and outline it.
Now cut that out. Once you do you should have the main frame and two smaller pieces. These will be added for support.
Now put one of the supports over the main frame. If you want the bolts in a pattern the I highly suggest you make dots and plan it out before you start drilling. I just wanted a line across the top so I went right at it.
Now put on the bolt and nut. Make sure you make it tight.
Now drill the rest. I put another bolt at the other end so it wouldn’t move.
Now take whatever bolts you put in out, and place your other supporter on the underside of the sword.
Make sure it is exactly line up with the other pieces of metal or it’s going to be uneven. Again, if you have a friend have him hold it tight.
If you make a hole at the end and one near the handle and put a bolt in them, it will hold it better than starting at one side and just going down.
Now put some near the the corners and some more close to the blade.
Once you get done with that take the supports off, and cut off or mod anything else you want to do with them. I chose to grind the bottom of the supports so the metal looks uniform and not like three chunks of metal bolted together.
I also decided to cut off the corners and later decided to paint it. If you do paint it I would use primer and a clear coat. If you expect to cut with it then expect paint to come off.
I also later hacksawed off the ends off of the bolts that were sticking out.
When you get done modding your supports put everything back together and put drill a hole in the handle. This will keep the handle together and help stop your hand from slipping.
Now put all your bolts in. If you have some washers mix those in too. Take your Socket Wrench and tighten the nuts as tight as you can get them.
Now look closely at your sword. If it has anything that needs ground off do it now. Remember, don’t leave it in one spot for too long!
Now it’s time to find the edge. Keep it and a 30-45 degree angle to the grinder. Do a swiping motion from one end to the other, and for every swipe on one side do one on the other. You don’t want you edge lopsided, and if at any time it gets hot let it off to cool some.
You can get it pretty sharp if you know what you’re doing, but it never hurts to use a file or a fine whetstone to make it sharper. Just remember, if you make it too sharp it will dull faster. And it doesn’t have to be razor sharp to cut, especially since it has a lot of weight behind it. Last thing, wrap some black tape around the handle.
Finished Product.
And remember, at anytime it gets dull you can use a file on it or take it back to the grinder. So don’t be afraid to swing the fucker.
Dec 03, 2007 6:09 pm - Because i’m trying to be a better person and because you obviously put a hell of a lot of effort into this egg AND because this can actually do some amount of damage, I will give you a 5*
I kind of had the buster swords design in mind, but didn’t want it to be to similar. I’m thinking of making another one twice the length, just have to find the metal =/
Dec 03, 2007 7:55 pm - Rivet the metal together, and ALWAYS use glue between riveted sheet metal like this, rivets aint that strong, but glue is very strong.
The bolts are a bit big.
And the handle doesn’t look very comfortable, maybe make some wooden side panels, or wrap it in foam and then tape.
4*s
Dec 03, 2007 9:31 pm - Fucking dumb idea. Plus pretty fucking common sense, you don’t need a guide to make a fucking stupid sword.
ec 03, 2007 10:48 pm - it looks like a huge pice of shit,
i will battel you with nothing but my gripOmatic
hamer.
you inspired me to get back to work on my war hammor
so 3***
lets have a battel
Dec 03, 2007 11:55 pm - I happen to have a street sign lying in my living room so 5*. People have been asking me what I’m going to do with and now I know. All I have is a file and hack saw though.
Dec 04, 2007 9:48 am - You did a really bad job on photoshopping the sword in the piece of wood... The lighting of the sword is brighter than the rest of the picture.
Dec 15, 2007 1:56 am - nice mang, i LOLed when u made sum of it out of a street sign. this could cause a lot of damage to a home invader......luv it man...5*
Jan 02, 2008 6:51 am - here are my swords and the rest of my weapons, used similar techniques when i made the swords, sheet metal but i folded the edge and, not having access to a grinder, they have no edges.
my scimitar:
my sword:
my dagger:
axe:
and here’s how i make handles, tiring but rewarding:
Aug 20, 2008 12:16 pm - This is a classic Egg I give it 5* cause it expanded my mind. Its a little small for my liking but its still cherry(no pun intended) Its a Rune type blade and I love those. It went from Crude to Rude in hours
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