Making some Shards of Narsil... the canon way?

[Chris Fields]

As for breaking a real sword you would have to make the blade extremely hard by heating and quenching it several times, this should make the sword brittle enough to break however there's no real easy way of controlling the break. The dremel option might work as metal tends to snap at the weak points but I seriously doubt you would be able to snap it along the length like it is in the prop.

the blade is stainless and does not harden in that manner. Also, for steels that do harden in that manner, you only have to do it once, not several times.

The only other way I can think of that you might be able to make a good shards replica is to make your own sword extra long from mild steel so cutting and shaping would be easy, once the bits are how you like them then heating and quenching them would work harden the parts making it seem like the whole sword was in one piece and then broken.

heat and quenching is not work hardening. and if it's mild steel, heat and quenching may not really effect the blade at all.

 

[Chris Fields]

just an FYI for everyone, I just went out and cut a stainless blade on my metal cutting band saw with the bi metal blades, cuts like cake... so if you have one of these band saws, that may be the way to go. Just have to carefully plan out how the cuts are so they are all possible.

 

[Jm419]

Hey, Chris, thanks for all the help. I've been doing some snooping around - my machinist suggests that unless I want to sand down the blade so it's no longer reflective, that laser cutting is probably not going to be the best plan there.

He did, however, suggest CNC cutting as a possibility. I have to still get in a little closer contact with him about it, but that might be a good way to do it as well.

 

[Sith_241]

You could probably EDM it also

 

[Zombie Killer]

There is always liquid nitrogen and a hammer.

 

[Jm419]

That strikes me as really dangerous, lol. I think the water jet is a pretty decent idea. I'll let you guys know what my machinist has to say.

 

[LVCIFER]

Hey Stivie, do you take on custom jobs? Like for example, if I were to mail you a brand new UC Narsil, would you be willing to cut it into a Shards of Narsil for a fee, just like you did with yours? I'm just curious.

 

[JBradley]

I use a dremel a lot and I don't think it'd be quite up to a task this big, at least not the larger cuts. I'd say get a die grinder or a legit cut off wheel and cut it that way.

 

[N2darkness]

Hey Stivie, do you take on custom jobs? Like for example, if I were to mail you a brand new UC Narsil, would you be willing to cut it into a Shards of Narsil for a fee, just like you did with yours? I'm just curious.

I have actually been contacted by others about doing this and I'll tell you the same thing. As it is very labor intensive and I burnt up 1 Dremel already I don't think its cost effective for me to do this. I still think that the waterjet idea would be best and to try and contact someone local on the cost.

 

[LVCIFER]

Hmm... I understand that, and can see your point. But what if I were to include a brand new Dremel and all of the cutting wheels (between 15-20) WITH the UC Narsil when I sent it to you, paid for completely by me?

This would NOT be included with the fee that you'd charge me for the actual labor, that would be 100% separate.

Would you consider it?

I'm not a "cheap" person. Let's just say that I'd be willing to compensate you very fairly.

The thing is, I already have a real, UC 'Shards of Narsil'. I have two actually, one on display, and the other brand new in the box. But YOUR version was extremely attractive to me because of how the final project came out. It was true to the movie. The workmanship, the display, all of it. It was top-notch, and I'm not just saying that to butter you up.

 

[Zlurpo]

Since this is back from the dead, how would a scroll saw with a metal-cutting blade do? I'd imagine you'd go through a lot of blades, but it seems like it would give really good control.

 

[N2darkness]

Hmm... I understand that, and can see your point. But what if I were to include a brand new Dremel and all of the cutting wheels (between 15-20) WITH the UC Narsil when I sent it to you, paid for completely by me?

This would NOT be included with the fee that you'd charge me for the actual labor, that would be 100% separate.

Would you consider it?

I'm not a "cheap" person. Let's just say that I'd be willing to compensate you very fairly.

The thing is, I already have a real, UC 'Shards of Narsil'. I have two actually, one on display, and the other brand new in the box. But YOUR version was extremely attractive to me because of how the final project came out. It was true to the movie. The workmanship, the display, all of it. It was top-notch, and I'm not just saying that to butter you up.

PM me and we'll discuss it further.

Since this is back from the dead, how would a scroll saw with a metal-cutting blade do? I'd imagine you'd go through a lot of blades, but it seems like it would give really good control.

Thats a pretty good idea and may be worth a try. It may be hard to cut a straight line though.

 

[Kit Rae]

The steel of the Narsil blade is hardened 420 stainless, in the 52-54 HRC range. Your average saw blade is not going to be much harder. There are steel cutting blades from scroll saws and band saws, but it would take forever, and a tons of blades to cut all the pieces. Stainless tends to work harden as it is being cut too. I would not recommend trying this. A diamond bladed tile saw can cut it too, but be prepared to take a long time.

A plasma cutter, water jet cutter, or industrial laser cutter are going to be the best choice. You can rent plasma and water jet cutters. A water jet will give the best edge because it won't burn the edge like the others will. If you have never done this before, probably best to take to a shop and pay someone to do it.