A claymore is a large two handed sword. Creating swords at home requires a great deal of time and a good selection of tools. This method will teach you how to make a basic claymore sword as an introduction to sword making. This homemade sword will not be especially sharp and is intended for display rather than actual use. Over time one will be able to create more intricate and complex sword designs as they hone their skills.
Find a leaf spring at the junkyard. A leaf spring is a curved piece of metal that is part of the rear suspension of a truck. Leaf springs come in various sizes, in order to create a claymore you will want the longest one you can find.
Cut off each of the rolled over ends of the leaf spring with an angle grinder.
Heat the metal with a blowtorch and use a hammer and anvil to beat the leaf spring until it is completely flat.
Use an angle grinder to grind the edges off one end of the leaf spring forming the tip of the sword.
Use the angle grinder to grind the long edges of the leaf spring in order to create a sharp edge all along the sword. Start grinding at the pointed tip of the sword and stop about 8-12 inches from the other end. This will form the handle of the sword.
Use the angle grinder to grind away at each side of the handle of the sword until the leaf spring is the same thickness as the broom handle for the entire 8-12 inches of the handle. This narrow area of the sword used to form the handle is called the tang.
Drill two holes in the tang with an electric drill. These holes should be placed about 4 to 6 inches apart and centred on the tang.
Cut off the bottom section of the broom handle so that it is the same length as the tang. Use a band saw to cut the handle in half lengthwise. Position one half of the broom handle on each side of the tang and use a pencil to mark the position of the holes. Drill the same holes into the broom handle.
Sandwich the tang between the cut pieces of broom handle with the curved end of the broom handle farthest away from the blade and use two rivets to secure them all together.
Round the bottom edge of the tang with the angle grinder.