Forging a Massive Damascus Guard for My Biggest Persian Fighter Yet (pt. 5)

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In Part 5 of this Persian Fighter build, I’m forging the pure nickel Damascus guard and pommel.

This is one of those parts of the build I was kind of nervous about. The guard is thick, curvy, and has to fit onto the blade at a long angle, so there are a lot of places where this could go wrong pretty quickly. I really didn’t want to mess it up and have to forge a whole new billet of nickel Damascus just to make another guard.

I start by forging the guard out of 1084 and pure nickel Damascus, using the hydraulic press, a round bar, and the horn of the anvil to stretch and curve the quillion where I need it. Then I forge the pommel, normalize both pieces, surface grind them, and use the laser to mark out the guard profile.

After that, it’s time for the part I really wasn’t looking forward to: fitting the guard to the blade.

The guard slot has to be milled on an angle, my mill bit just barely makes it through, and I end up making a custom wooden punch out of a 2x4 so I can hammer the guard on without damaging it. It takes a lot of hammering on, hammering off, filing, milling, and sneaking up on the fit, but the guard finally comes together nice and tight.

Then I start fitting the Tasmanian Blackwood handle to the guard and blade. That turns into its own little challenge because the guard fit-up is curvy, the tang is curvy, and the handle slot has to be drilled and broached carefully so everything lines up the way it should.

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May the forge be with you.
Bye-bye.

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