Making A Sword Cane***Very Large 35+ Pix***

[Tim Crosby]

 One of the fella's here asked me about making a Sword Cane I was getting the pieces together to make another and decided to take Pix along the way. The blade was shaped from an old Corn Knife. 

The blank for the case, the corn knife with the shape of the blade on it and some candidates for the handle.



 In the process of shaping the blade.



 The blank split on the band saw.

[Tim Crosby]

 Fitting the handle on the blade, I left out the part about laying out and cutting the opening for the blade in the handle by mistake. Any question just ask.



 Starting to cut the opening for the blade on both sides of the blank.





 Fitting the blade into the blank.





 This is the spring that will hold the blade in.



 The case glued and clamped.

[Tim Crosby]

  The blank for the tip mounted on a Pen Mandrel. It is a piece of Mulie antler with a 1/4" hole drilled through it.



 Brass plate that will be the ferrules.



 Sawing them out and fitting them.

[Tim Crosby]

 The tip rough turned.
 


 The ferrules rough fit and the blade fit to the handle. Three Steel pins hold it in place with some Epoxy for filling. 





 Here you can see how the case was cut to Eight sides and tapered getting ready to round it out.
The sides were cut on a Table saw and then tapered on a jointer.

[Tim Crosby]

  Most of the shaping was done with rasps here in the clean up mode with a scraper. Behind it you can can see the piece of angle iron I used to find the high spots, smoke it up run it on and scrape. I probably did it 2K times.



 Almost finished and ready for sanding. You can see the Brass ferrule on the end it is attached with 4 screws.



 The Brass bolt being filed to fit, it will go up through the tip and into the case.







 Laying out the locations for the Pewter bands that will be poured in place.



 A pattern made from file folder card that will wrap around the case  and be taped in place.

[Tim Crosby]

 A pattern taped in place, bankable molding clay will be wrapped around it to finish the dam.



 After the pour, you can see the dam in place. Also the screws holding the ferrule.



  Cleaned up a bit and what I use to make the pours with.





 Not a very good Pic but you can see all 4 bands in place.



 The patterns for the diamond inlays on the left and the inlays themselves.



 Starting on an inlay, a line divides the case and another crosses it to align it.

[Tim Crosby]

 On the Left in this Pic you can see where the tip will fit. I used a 3/4" hole saw to cut it, just be sure you keep the drill level/perpendicular. Also shown is the block I use to bend inlays to fit round or curved areas. I center the annealed inlay in it and press a round piece of bar stock into it bar, you can see it to the Right just below the marker. This one is Cherry that was drilled through with a 5/8" bit and cut in half or there abouts.   



 The first one in.



 And all 6 in place.



 Sanded to 320, the grain was raised a number of times along the way and painted with a water based alkaline dye to raise the grain one last time. The Yellow will be sanded away before staining but some will stay.
 


 Soldering a piece into the screw slot in the top of the tip.

[Tim Crosby]

 Finished Pix in the works.

   Tim

[msellers]

This was very informative, and help straighten up a few questuons I had about this.
Thank you for sharing this with us all, and giving additional inspiration to those of us who are into the oddities.
Mike

[Marcruger]

Way cool Tim.  Now I know what you've been spending your time on.   :-)   More pictures!   

[Tim Crosby]

This was very informative, and help straighten up a few questuons I had about this.
Thank you for sharing this with us all, and giving additional inspiration to those of us who are into the oddities.
Mike

 Mike if you decide to try one and have questions just PM or email me.

   Tim

[msellers]

This was very informative, and help straighten up a few questuons I had about this.
Thank you for sharing this with us all, and giving additional inspiration to those of us who are into the oddities.
Mike

 Mike if you decide to try one and have questions just PM or email me.

   Tim

Will do Tim, thank you very much for everything.
Mike

[Curtis]

Nicely done. Tim!!!  Darn near perfect.  Wish I had seen it earlier.

Curtis