
Making a sword: Forming - Finishing - Testing - Polishing - Embossing - Engraving - Hilt & scabbard - Assembling
Adorning with Mother of pearl: cutting, breaking and shaping - applying - filling - polishing, glossing - variation
Making the sword - putting on decorations on the sword
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Unlike assembling a standard Darb with a wooden grip - with a stainless steel guard and pommel where the pommel secures the entire hilt by being fixed onto the screw ending the tang of the blade - the Darbs with embossed decorations are subject to an other assembling procedure. This page illustrates this different method.
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After the blade is judged fit to be assembled, the supporting handle must be prepared
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So, a piece of wood must be shaped to a convenient shape and size -
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- and when it fits into the copper decoration, it is ready for the next step. (observe that the embossed decoration was not plated in any color, this because it was used for this demonstration uniquely ) |
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Drill a thin hole so the blade can be turned and fixed into it with the big wood screw that was welded at the tang's end.
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After a verification, drill a large hole so the tang can be inserted Significantly, form a thread on the handle to ease the flow and adhesion of the resin (see later) |
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Make sure everything will fall in place, some last adjustment might be required, like evening the blade's end to make it nicely suit the top of the handle.
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When it is assured that all corresponds, the handle may be screwed onto the tang
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And when it is sure that all fits together, it is time to make the final assembly - bonding the embossed copper decoration onto the handle. |
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To bond the parts together, the same rubber resin concoction acting as a shock absorbing surface during the embossing procedure is here coming into use as an adhesive. The hot melted compound is poured into the decorative piece, and after this the handle is inserted, cooled in a water bath to harden, and later on cleaned from excess.
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At this point the process for this stage is finished. Note that scabbards ornamented in full with those decorations will be submitted to the same bonding method after it was made sure they fit together.
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