I’ve decided to add a crossguard to the poniard. I like the look of copper and dark steel, so I’m going to make the crossguard in copper, from a half inch thick bar.
Since my 1045 carbon steel bar is half inch by half inch bar, I’ve begun by drilling a half inch diameter hole in the copper. I began with much smaller drill bits, and worked my way up to the big hole. Of course, this hole in round, and it needs to be square, so I’ve ground a nice flat on a spare bit of the same 1045 steel bar to use as a makeshift broach to turn the round hole square (see it above laying on the right side of the jeweler’s saw). To help with this, I’ve used my jeweler’s saw to cut opposite square corners most of the way through
Above is the completed square hole. Quite a bit of work!
Thanks for Looking!