for over thirty years.

I've created weapons for over two hundred feature films. This is Man at Arms.

The Buster Sword is absolutely ridonkulous. The blade is six feet long,

twelve inches wide.

I'm doing a cutting edge of a steel blade

with 1075 spring steel.

That'll be inserted into the blade and riveted down.

This is a plate of 6061 aluminum that will be plated

milled out to shape here. This will all be wrapped in a band of bronze.

I'll do a technique called chasing repousse.

Hammering out these little squiggly lines. Just a simple little sword.

I got a piece of three eighths of an inch thick 7075 aircraft aluminum.

I have six feet by twelve inches. Chopped off one end of it to give a triangular tip.

I brought Bill in. We call him 'William the Elder.' He's a retired foundry man machinist.

I had Bill machine a slot an eighth of an inch wide by over an inch and a half deep

into the side of the plate.

We have a bolster or a hilt that's made out of

one-inch thick aluminum. We milled a three-eighths slot

three inches deep into it.

Because this sword is so ridiculous it just needs a longer handle.

We have eighteen-inch long handle on this made out delrin plastic.

Took a rough ingot of bronze and forged it out to the pommel and ferrule.

Bronze is a little tricky.

You're not supposed to forge cast ingots,

but we didn't have the time to cast the pommel

with lost wax casting

so I'm going to take a big chunk of bronze and forge it into a ball for the pommel.

And I'm going to take a smaller chunk of the ingot

and forge it into the tube for the collar.

That'll be used for the front of the handle.

I had my assistant Brian turning

the bronze ferrule and pommel on the lathe.

Then I took the rough trimmed pieces to the belt grinder, trimmed them up,

then used a scotch bright belt to refine them.

I took the vice off the vertical milling machine and clamped the sheet of

aluminum up there and used a ball endmill

to mill in decorative lines on the blade.

We have to heat treat a six foot length of eighth inch thick by three inch wide

1075 steel.

Grind it out a razor sharp edge.

Then set that into the milled slot on the edge of the blade and rivet it down.

Due to the size of the Buster Sword, I couldn't bring it over to the mill

or the drill press when it was fully assembled.

So we had to use a portable drill.

We burned up three drills trying to hand

drill through that solid block of aluminum.

After we had the whole Buster Sword assembled, we hit it with the chemical to

darken the aluminum to patina it to give it a dark steel appearance.

I'm a pretty strong guy but just carrying the Buster Sword out of my

workshop pretty much wrecked my back and arm. The thing probably weighed

seventy-five, eighty pounds.

This has got to be one of the most ridiculous,

huge, sword blades I've ever made.

I'm pretty pleased how it came out.

I don't think i want to do another one.

I can mark this in my baby book that yeah,

this one's done.

Thanks for watching Man at Arms. Be sure to subscribe.

Tell me in the comments what weapon you'd like to see you next.