We always enjoy watching rusty metal objects being reworked into new ones. In this satisfying blacksmithing video from Faraway Forge, they start off with a big old industrial hook, get it fiery hot, and hammer it into a bar shape. From there, it takes huge amounts of handwork to shape and hone it into a blade for a katana.
Wootz steel is a tough high-carbon metal that’s been used to make swords since the 5th century BC. FZ – Making Knives used the technique to create a beautiful and strong katana by melting down an ingot made from ball bearings, forging it into a blade, then honing it to an incredibly sharp zero-point edge.
For those unfamiliar with ancient Egyptian history, a khopesh is a sickle-shaped sword that evolved from battle axes. Black Beard Projects created this replica of the deadly weapon by forging bronze alloy, pouring it into a sand cast made from a CNC-milled wood form, then grinding and polishing it to a shiny finish.
We love watching rusty old objects get turned into shiny new ones. In this video from Random Hands, they transforming a weathered railroad track into an elegant Japanese weapon. The process starts by cutting off a hunk of steel, forging it into a bar shape, then gradually shaping and grinding it into its final form.
The energy sword is one of our go-to weapons in the Halo series. We’ve seen lots of cool replicas of the sword over the years, but they’re usually toys made from plastic. Hacksmith Industries went above and beyond with their working version of the iconic sword, which is basically a quad-blade version of their plasma lightsaber.
The choreography in Star Wars lightsaber duels has isn’t exactly realistic. The guys at Corridor Crew enlisted stunt coordinator Luke LaFontaine to help choreograph a fight scene that much better captures realistic swordplay tactics and how you might wield a lightweight plasma weapon. Then, they cranked up the VFX wizardry.
Leaf springs from cars and trucks might not offer the best ride quality, but they make some pretty awesome weapons when recycled by a skilled bladesmith. Faraway Forge crafted a beautiful Japanese tanto-style knife from one such rusty piece of metal. We love how he kept the pitted texture as part of the finished piece.
Inspired by a weapon in the RPG Genshin Impact, Ilya and Matt of That Works created their biggest sword yet. They crafted the hefty claymore-style weapon using traditional bladesmithing techniques. The two-handed sword has an enormous angled blade, and an ornate handle with a gleaming red glass sphere a its center.
We love how metal can be used over and over again. After one object has served out its life, it can often be melted down and turned into something new. In this clip by metalsmith Random Hands, he shows us how he took a rusty link from an old piece of ship’s chain and hand-forged it into a beautiful new samurai sword.
Swordsmith Ilya Alekseyev of That Works walks us through the process of making the weapon that won the Best Sword of the Year award at Bladeshow 2021. The ornate, hardened steel sword incorporates a beautiful mosaic Damascus, along with incredible engraving and inlay work.
The gigantic Switch Axe from Monster Hunter would likely be impossible to wield in real life. To solve this problem, Crafty Transformer built a lightweight replica of the transforming weapon out of cardboard, complete with the ability to convert from a sword to an axe. Though we don’t recommend lighting this one on fire.
The coiled sword in Dark Souls III is one of the coolest fantasy swords we’ve seen. Aleksey from Bellerophon Studios demonstrates a number of classic blacksmithing techniques to bring this awe-inspiring twisted blade to life. Matt from That Works provides the informative narration.
Ilya from That Works turns to traditional Japanese blacksmithing methods to create a short sword known as a tantō. To accompany the crafting footage, he offers an in-depth lesson on the history of these weapons and their swordsmiths. The finished sword is a true work of art – and deadly sharp.
Those massive swords you see in anime look cool, but they’d be totally impractical in the real world thanks to their weight and shape. But that didn’t stop Allen Pan from coming up with a solution. After asking his pal Rob to fabricate a Buster Sword, Allen bought himself an upper-body exoskeleton to help him wield the hefty blade.
Inspired by the Jackie Chan movie The Spy Next Door, maker JLaservideo created a sword that stores like a belt. The tempered steel weapon works like a tape measure, bending around his waistline, then maintaining a semi-rigid shape when deployed. We’d be afraid of cutting ourselves pulling it out of its sheath.
The guys from Australia’s How Ridiculous have made a business out of dropping stuff off of a 150-foot tower. In this clip, they got their hands on a massive sword built by Alec Steele and proceeded to put it to the test to see how deep it would plunge into things on the ground below. Perhaps most impressive is how durable the sword is.
The swordsmiths of That Works take on another great video game inspired build, this time crafting the Lothric Knight Sword from Dark Souls III. Rather than an over-the-top fantasy weapon, this impressive and strong straight blade is as practical as a real world sword that could have been wielded by an actual knight.
After digging up a rusty old nail from his yard, maker Bobby Duke transformed the nasty looking old piece of scrap metal into a beautiful miniature sword that’s fit for a tiny warrior. Along the way, he made a custom forge from a paint can, some concrete, and blow torches.
When he’s not making glowing katanas, Keaton Goddard of Faraway Forge likes to create new tools and weapons by recycling stuff from the junkyard. Watch as he makes a beautiful rapier from a rusty old leaf spring, with a hilt crafted from bent bicycle sprockets, oak, and a trailer towing ball.
Mustard’s playful metal bookends make it look like you’ve pierced your collection of books with a samurai sword. The trick to the illusion is that the metal hides inside of the end books, and the faux sword parts hold in place with magnets. They’re perfect for storing your copies of Bushido and The Art of War.
Faraway Forge envisions a universe in which battles are fought with light-up katanas. He first forged its two blade sections, tempered them to different finishes, and welded them together. He then sandblasted the handle, and installed electroluminescent tape and wire to give it an awesome red glow.
Cloud’s Buster Sword from Final Fantasy VII is one of the coolest weapons in gaming history. While a real world version would be too heavy to effectively wield, one made from cardboard is totally manageable. Watch as Crafty Transformer turns a bunch of corrugated paper into a lightweight replica of the iconic combat tool.
(PG-13: Language) The swordsmiths at That Works pay tribute to The Witcher by forging an impressive replica of Geralt’s steel blade. They even folded some meteorite into the steel, giving it an even more mystical appeal. The build even includes a detailed replica of Renfri’s broach attached to its hilt.
Ever since seeing The Sword of Exact Zero in The LEGO Movie, swordsmith Michael Cthulhu has contemplated making a larger-than-life X-Acto knife blade. With a sponsor in hand for his video, he finally took the time to make his cutting tool for giants a reality. He’s auctioning it off for charity to help save animals from Australia’s fires.
Russian YouTube channel Creative Forging shows off a neat technique for creating an awesome dragon scale patterned handle from a solid bar of steel. The trick involves making a series of 45º cuts into the metal, then heating it in a furnace and twisting it while still pliable.
After their run on Man at Arms Reforged, Matt Stagmer, Illya Alekseyev, and the swordsmiths of Baltimore Knife and Sword are back with their own channel, That Works. Their first build is an impressive replica of Asta’s imposing sword from Black Clover. It’s not as slickly produced as their previous series, but a bit more informative.