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Aluminum Dagger

This is how I made a dagger out of aluminum-which happens to be one of my favorite projects. It took a bit of work, but the end result is beautiful. It even starred in a movie already!

The first thing I did was find a picture of a dagger. After browsing the internet for a couple hours, I eventually went with one that I liked the look of.

Learn how I made a dagger by casting it out of aluminum - thearmourman.com/aluminum-dagger

I then printed it, and cut it out with a exacto-knife. Unfortunately my exacto knife is quite dull, so I have to push pretty hard.

Learn how I made a dagger by casting it out of aluminum - thearmourman.com/aluminum-dagger

After tracing it onto some wood, I proceeded to cut out the shape with a bandsaw, and then shave down the wood into a dagger shape using hand tools and my trusty dremmel.

Learn how I made a dagger by casting it out of aluminum - thearmourman.com/aluminum-dagger Learn how I made a dagger by casting it out of aluminum - thearmourman.com/aluminum-dagger

I then created the mold that I was going to use to pour the aluminum in.

Learn how I made a dagger by casting it out of aluminum - thearmourman.com/aluminum-dagger Learn how I made a dagger by casting it out of aluminum - thearmourman.com/aluminum-dagger

After clamping the two halves back together, I then melted some aluminum and poured it in. Here is the initial result after cutting off excess aluminium.

Learn how I made a dagger by casting it out of aluminum - thearmourman.com/aluminum-dagger

After a ton of sanding and polishing, I eventually ended up with this.

Learn how I made a dagger by casting it out of aluminum - thearmourman.com/aluminum-dagger

I then added some leather to the grip, and I embedded some jewels in the crossguard.

Learn how I made a dagger by casting it out of aluminum - thearmourman.com/aluminum-dagger

I plan on making another one at some point. Well, maybe when I get more aluminum...


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Aluminum Dagger

7/5/15

This is how I made a dagger out of aluminum-which happens to be one of my favorite projects.

A dagger casted out of aluminum- thearmourman.com/aluminum

Aluminum Sting

8/20/16

This is my attempt to make the sword Sting from the Lord of the Rings out of aluminum.

Sting casted out of aluminum- thearmourman.com/aluminum

Making a Mold for Casting Aluminum

9/11/16

This is how I make a sand mold for casting aluminum.

How to make a mold for casting aluminum- thearmourman.com/aluminum

Making a Flask for Casting Aluminum

10/6/16

This is how I made a wooden flask that is used to pack sand for casting aluminum.

How I made a flask for sand molds- thearmourman.com/aluminum

How I Made My New Furnace

10/23/16

My new, upgraded furnace is ready to melt some aluminum (and brass, and maybe copper)! Here is how I made it.

How I made my new aluminum melting furnace- thearmourman.com/aluminum

Making an Aluminum Battle Axe

1/9/17

I made this battle axe for my brother for Christmas. With an aluminum head and a oak haft, it almost feels like the real thing.

Learn how I made an aluminum battle axe- thearmourman.com/aluminum

Making an Aluminum Plaque

1/14/17

I made an aluminum plaque for my mom for Christmas. Here's how I did it.

How I make aluminum plaques- thearmourman.com/aluminum