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Del's Cutlass

A cutlass, roughly 32 inches long made from 4140 steel
for Del Merritt of The Sea Dogs.The sword features a mild
steel guard, full tang and hand-formed, 2-piece, maple
handle that was stained and ployurethaned.
Forged sword prior to finishing.
Sword mocked up with the mild steel guard for
measurements to make the maple handle.
One side of the two piece maple handle mocked up
for fitment. Cardboard is used because it's much
more forgiving than mild steel and doesn't mar
the work already completed on the sword.
Mocking up the guard and handle.
Flip side of handle mock up.
Close up of butt showing exposed tang end, handle
and guard detail.
All polished and shiny!
Close up of the mild steel guard.
Finished sword with scabbard.












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