[TheForge] Shortcut Sword?

[Ralph]

At 07:27 PM 11/3/2003, you wrote:
>Not to discourage my Son and make him question what good all this
>metalworking gear is, I agreed to make him a sword.
>
>At this point I have no interest in making a sword so I'd like to do
>something quick but decent.  Fortunately he's 7 so it won't have to be big.
>
>I'm thinking of cutting the profile from a 1/4" leaf-spring and then somehow
>getting the edges beat down with the 50# little giant, then taking a bull
>grinder and finally the sander to the mess.  Maybe I'll pound the whole
>thing thin before cutting to make it lighter.
>
>For heat treat I thought I'd maybe just heat it up to red and let it air
>cool.  He won't be doing any heavy duty edge abuse (I hope).
>
>I have never made a long flexible thing before and I don't know what to
>expect from the leaf spring steel in that application.
>
>Any suggestions?  (ideas for *easier* methods *most* welcome).
>
>Thanks -
>Ed

Aluminum flat stock, grind away all that is not a sword.... Can even be 
finely gound and polished... He is after all only 7 so  he will not need a 
'cutting sword'.

Ralph