Bad Leaf Springs Make Good Swords

Note: This project is essentially for novelty purposes only. We do not recommend using a homemade knife or sword for any practical purpose.
5160 Carbon Spring Steel. In our office we always thought this material was the steel that made our trucks springs and suspension components. However, spring steel is also used for other purposes and is more commonly known to blacksmith's as it's much more durable and prone to less breakage as compared to a high carbon steel (aka: 1095 to the blacksmith's of our modern world). Where do hobby style blacksmiths get this material? You guessed it - leaf springs from or old cars & trucks like chevy or ford leaf springs.

YouTube Video's, pictures of swords & knives crafted at home from amateur blacksmiths and even the pro's. But how do they really do it, and why the sudden increase in its popularity? Well who doesn't want a cool sword? And its recycling which is a hot topic these days. So SDTruckSprings.com staff thought we would take a further look into this, and see if any of our viewers had heard or even done this, or maybe we've intrigued you into how its done....

Once you've found yourself an old leaf spring, get ready to make new use out of it. There are 2 ways to do this, one is the tradiontional hot method, melting the steel & then taking a sledge hammer and pounding it straight. Blacksmith's have used this method for years when it comes to bending steel, or even chiseling edge's (will get into that later).

Or you have another option that requires more strength and is also a method that has been used for years. Place you spring on an anvil on a very hard flat surface you'll use are your guide to making the spring straight. You then take your sledge hammer or steel hammer, and behing to smack the curved metal along the anvil making it straight. Now doing either or these methods will provide you with a solid steel base you start your sword.

Now all that's left is giving your leaf spring sword and edge and select its length, some have even made knives and daggers, or huge swords. When selecting your size always keep in mind that your length of the sword includes the length of the blade, and the width of the guard, length of the tang and a 2-inch pommel stud. After cutting you then lay out a sword profile using a fine tipped marker. After you get your cut done and up to your sword/knives spec's use a bench grinder, and rough grind the edge angles of the blade after then finish grind the blade and tang with 80-grit abrasive. After you finish grind all that's left is selecting your handle. Many people have used wood, more steel, or even bone to construct a durable and nice handle.

It's just amazing and just goes to show you that almost anything can be recycled and givin new use. We have scoured the net and these are some of the blades forged from old car & truck leaf springs we thought we awesome and the best we've seen. Contact us if you have done this before or have a pictures of your own sword, or maybe even your own DIY video.

Some finished swords and knifes: