Temple of Doom Indiana Jones Machete

New batch of raw cuts came in for the new design. Going to get some decent metal polish for the blade, but I was able to get a new sander so I can taper the grips down from the pommel to the guard.
 

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These look amazing! If they look this good now I can only imagine the final product.
 
All right, got a few hours over the past several days to work up the second prototype! Still a bit to do shape wise, but it tapers from a bit over an inch to a bit over .5 inches. The blade is a touch longer on this one as well, so it is just about 31 inches long.

Cutting the aluminum this thick definitely increases the tolerances a bit. So there is a lot of clean up.
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Okay, so some good news, and bad news.

I think, unfortunately, I won't be able to reliably add the groove into the aluminum. As they aren't forged or hammered, the aluminum, while a high quality alloy, is still soft compared to steel. I broke two blades getting the groove in, by either going through the aluminum, or because removing the material creates too much stress at the guard, causing it to bend.

However, I can still add the edge, and highly polish the blade. The screen used blade looks very shiny. This was a quick pass with an old polishing wheel, so I think with a new one, they'll get very reflective.
 

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The lack of groove doesn't bother me at all. At least you tried it. Those look incredible!
 
Polishing up blades. This is with 1000 wet sanded. I'm gonna step up to 2, and 3000 wet sanded and polish up with some Flitz to hopefully get a higher shine.
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Hey all,

I have to move unexpectedly. BUT! The good thing is, the temp shop area I am in will allow me to sand/grind outside. So I can really dig into these in the coming weeks.

The metal parts are all assembled, I just need to cut and install the grips to start sanding/grinding/polishing everything down.
 
Hey all!

I'd love to do more of these. Only had two folks commit to the first run, which ended up being a blessing in disguise.

My life kinda got upended unexpectedly. So my tools are all over the place; some in storage, some accessible, some missing. Hah.

I'll definitely update the thread if I have the opportunity to make more!
 
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