Also from 2007, the companion piece to the interveiw below.
Recently we talked with a bloke who makes swords. Didn’t think there would be much call for that these days, did ya? But there is, in fact, from interested collectors all over the world. But what about making these swords? Our smith held that info close to the breast and wouldn’t reveal his secrets, but we have many other sources to tell us how the medieval swordsmith went about his work.
First, you have to start with a forge. Wood burnt down to charcoal and then kept very hot with the subtle manipulation of air through the fire is essential. A Master in his field would employ apprentices and journeymen, learning the trade from the Master, living with him and exploring all aspects of metal work. They’d help with fanning the forge, keeping it fed, helping to manipulate the metals, and, of course, cleaning up after their master. This wasn’t an ordinary smith. He wouldn’t likely be shoeing your horse. And although many might consider smithing an art and craft, the swordsmith was a cut above this.
Carbon steel was the metal of choice. There was iron a’plenty to be had in Europe and England and with the addition of carbon from the forge, the metal alloy was created by the constant striking and melding of carbon and iron, the turning and folding on itself, precisely as one would make a pastry with layers of dough and layers of butter folded over one another and rolled out time and again. This is called pattern welding.
The raw steel is beaten into a rough shape. Then the blade is tapered for the tang (the part that will become the hilt) as well as the tip. This is done by drawing out these portions by careful hammering when the metal is hot.
When the tang is complete, a smith will use a tap and die set to poke holes in the tang in order to fasten the wood blocks that will become the grip. The smith will then work the blade, working only small sections at a time, heating it up to a red-hot temperature and hammering it to shape and length, constantly flipping it over to even out the shape and thickness. Heating the blade and allowing it to cool is known as normalizing the steel, which allows the crystalline structure of the steel to smooth out. When the steel is repeatedly heated, it allows the iron and carbon molecules to combine, creating a steel alloy.
Before the next phase of grinding and polishing, the steel is annealed. This means it is heated again and allowed to cool very slowly, as long as a day, before it can be soft enough to cut or engrave. Also the edges are filed to a thin width in order to allow for sharpening.
Then the blade is again heated and then stuck into a bath of oil (not water) called the quench tank. The oil in the quench tank causes the blade to cool rapidly and evenly. This is a dangerous point in the making of a sword and where the master differs from the apprentice or journeyman. It can’t be taken out too soon or left in too long. If the blade is not evenly cooled at this point it can warp and then the process must begin anew. This makes a very hard blade and may then be tempered. It is heated again—though not as hot as before—and quenched again. This is repeated several times, making the steel even harder.
After the swordsmith is satisfied, the making of the hilt can begin. The guard is either welded in place or held there by the hilt. Blocks of wood are fastened to the tang. A pommel is last and keeps all snug. The topmost part of the tang is bent over and hammered, holding the pommel in place. The wood for the hilt is shaped and smoothed and then covered in leather. Then the blade itself is polished and sharpened.
The sword is then ready to be presented to its owner. A sword was not merely a weapon to be used in war. Any Freudian can tell you that such a symbol was also of masculinity and power. It represents the owner’s skills, his mastery over others. A sword is used to make a knight, of kingship (as in Excalibur in the stone), of mission (the shape of a sword held hilt up is in the shape of a cross), and of death.
So of course I use the lack of this weapon for my character Crispin to show his powerlessness, his emasculation amongst his peers. And how he rises above that lack.
I like swords for their physical beauty as well as those features cited above. A decent sword cannot be made on an assembly line. A man with a forge must still be employed to make this weapon. I like that tie to the past. I like that there are still some things that must be made this way, as they have always been made for thousands of years.
Some sources: Uden, G. A Dictionary of Chivalry, New York: Thomas Y. Crowell Co., 1968., Norman, A. V. B., The Medieval Soldier. New York, 1971., Oakeshott, Ewart, Records of the Medieval Sword, Woodbridge, 1991., Oman, C. W. C., The Art of War in the Middle Ages, Ithaca, NY, 1953., Beeler, John, Warfare in England, 1066-1189, Ithaca, NY, 1966., Hrisoulas, Jim, Pattern-Welded Blade: Artistry In Iron, Boulder, CO. 1994.,Bezdek, Richard H., German Swords and Sword Makers: Edged Weapon Makers from the 14th to the 20th Centuries, Boulder, CO., 2000