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Making a Excalibur letter opener Making a Excalibur letter opener

Making a Excalibur letter opener - PowerPoint Presentation

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Uploaded On 2016-09-13

Making a Excalibur letter opener - PPT Presentation

Prepared for Ken Jeberg By Ken Jeberg Trades Technology Teacher Education How to build a Excalibur letter opener Our objective Is to assess the skill level of the students with a simple project and work our way up from there ID: 465400

project piece blade letter piece project letter blade metal grit edge picture shape material guard polishing solder cut rod sword opener hammer

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Slide1

Making a Excalibur letter opener

Prepared for

Ken Jeberg

By

Ken Jeberg

Trades Technology Teacher EducationSlide2

How to build a Excalibur letter openerSlide3

Our objective

Is to assess the skill level of the students with a simple project and work our way up from there.

Also this gives them opportunity to learn on some basic hand

and power tools, before you get into the next projectsThere is much safety learned here also Slide4

Material list

Need a piece of 3/16” steel rod

¼” shelf pin

Bullet shell or whatever you have on hand that is dimensionally suitablePolymer clayBuffing compound : 400 grit, 800 grit, 2000 gritSlide5

Tools for project

Vice grips

15 pound persuader

Full tank propane burnerRuler20 oz. hammerBlack marker Wood c-clampStationary vice

Portable drill

Fine model file

Buffing wheelSlide6

Procedures for making the Excalibur letter opener

First you heat up the metal rod on the propane torch until the metal is glowing red

Slide7

Then you pound the metal until you get the metal to reach its required dimensions

As you hammer you want to hammer the metal out at

least 10 centimetersSlide8

As you hammer you need to check the blade against the edge of the ruler to make sure your sword stays strait.

You want the thickness approx. 1.5 mm

Width 1.2 cm

Make sure you hit the rod squarely and not off to the center

o

r the rod will hook to the right or left

.Slide9

Now we shape

the blade

Mark 3.5 centimeters in the bottom part of the sword :

This is going to be the smooth part of the letter opener, so when you open a letter you don’t cut your fingers Slide10

Shaping the blade

Make sure your piece is securely fastened before you begin the sanding

Before you start sanding your rough edge you can scribe in a line 3 mm in all around your sword where you want your sharp edge. This allows you to have a reference part so you don’t make to big of an edgeSlide11

Now you clamp down on your piece as shown in this picture :

All you need is a fine hobby file, any bigger would take to much

material off, and you would damage your projectSlide12

Use your

dremmal

along the edge where your blade is being ground in, again make sure your project is secure.

When using your

dremmal

do light passes the full length of the blade

The grinding disc is preferred for the handle piece.

Again do light passes so you don’t take to much material

at once, that way you can make a nice rounded profile

Use a regular buffing wheel, with some buffing compound

and

you

can really make a nice smooth shiny bladeSlide13

Form the guard

Heat a shelf pin until it glows cherry red

Pound the material on your sledge hammer head until

You achieve this shape in this pictureSlide14

You can see here what you want the form guard to look like, so it is just a matter of putting this piece in a vice and clamping it down securely and filing it to its

a

ppropriate shape

The above piece you can see has a hole drilled to size

So you can slip the guard up the handle :

You want the holes so the piece is pressed fitted on slightly

Then you use regular acid flux solder to bond the pieces togetherSlide15

Cut the pommel

You can use really what you have on hand, but this picture

They are using a shell casing

There is no way set in stone to cut this off, they are using a

drill

and a

hack

saw

to spin this end off for this project

Once you have your piece cut you drill a tight hole in the one end

And press it on as in like as in the picture.

When you have this piece in place you solder it on with acid flux solderSlide16

Solder, polish and clay

Make sure your joints have been soldered strong, remember

your

joints are

the pommel and guard

Then you start the polishing process:

Use a regular polishing wheel, starting with a

400

grit polishing compound and finishing with

a

2000

grit compound

You can polish until you get your desired finish, there is no time frame really with polishing.

The next phase is to shape some dark clay on the handle like in

The picture provided

Also some blue clay in the pommel so it is flush to the outer edges of the

circle

Then you bake this project in the oven at about 400 degrees C for about 25

min, take your sword out and you are done

Slide17

Go open a letter