Month: June 2025

Ups and Downs

So, in all my years of doing this crazy job, I’ve never had a sanding belt break. Today, I had two of them fail on me.

Both of them failed in the same place. Right at the seam. I don’t know if it’s because they’re old or because I should have used a coarser grit for this stage of shaping or some other reason I’m not seeing. What I do know is that Those were my last two belts and I’m not sure how I’m going to finish the project. I’m not exaggerating when I say I’m broke right now.

The good news is that I got the seraph blade all sanded around the edges and I can at least get it measured and marked up for shaping. It’s really important that all those edges make a nice 90 degree angle with the sides (which we know for sure are flat). That lets me make sure I get the edge of the blade right in the middle and not curving off in one direction or the other.

So what now? Well, I shut my machine off and cleaned up the workshop, swore at the broken belts (as is customary), and went for a shower. Now I’m gonna work at clearing my head and conferring with my wife about what sort of budget we can spare for this project. I can’t afford to sink money into it until it’s done which was my way of doing things before financial disaster hit us.

Wish me luck. I’ll try to find a way forward.

Are You Crazy Enough?

I’ve got some updates and an offer for you. Let’s get to the progress report on the wakizashi first.

No, I didn’t break it. That’s an extra chunk of Plexiglas in there.

At last! The pattern is all cut out. Edges ain’t pretty yet but that gets fixed next.

I like keeping aside the pile of all the off cuttings to see how much plastic gets removed. Some of these bits are big enough to make a pendant or small decoration. I try not to waste plastic unnecessarily.

Now! My proposal …

I’ve mentioned before that my wife and I are struggling financially. If I were back home in Canada, I could put up my Patreon or PayPal and you could simply contribute a buck or two if you felt like supporting my work here. But in Finland, that’s illegal.

Yep. I have to sell a product or a service. I can’t legally take donations. Sucks eh?

So I have to take more of my very limited time and energy and try to make an additional product to sell in hopes of getting a trickle to take some of the pressure off.

That’s why I’ve decided, for the first time, to offer tutorials on how to do what I do, step by step. It’s difficult. It requires a degree of insanity to stay patient and stick with it. But it produces results that you cannot get by any other means.

This kind of clarity, structural strength, and inner “glow” cannot be produced by 3D printing or moulding and casting.

What do you think? Are you crazy enough to try it yourself? Or perhaps just curious about the techniques? Would you be interested in some tutorials?

A Tale of Tragedy and Madness

Today, I’m going to tell you about my day using pictures.

Screenshot
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Yep. It’s been that kind of day.
I’ve already repaired this strap system once and I don’t have the time or materials to do it again. I have a replacement part coming to me via Temu. Don’t throw shade on me for that. I am BROKE and I literally can’t afford anything better. No, there is nothing available locally in bumf*** Finland. The next cheapest thing I could find was from Amazon at 40€ plus shipping and it would arrive while I’m visiting my relatives in Canada.
So, for now, we’ll have grouchy post-apocalyptic Shrek.

Here’s an update on the sword.

Git r’ dun. Can I have a beer now?

Wakizashi Work

Angel blade all cut out, now it’s time to work on the wakizashi!

Got the modified Clariel seraph blade cut out as much as is practical with the plunge cutter. Now it’s time to tackle the wakizashi.

Slow and steady wins the race. There are several factors that dictate the pace of carving PMMA (Plexiglas).

For me, the first consideration is how much work my body can do each day. Because I’m not well, I have strict limitations on my endurance. I still have to do other things each day like prepare food, shower, clean, take care of my cats, and go grocery shopping. If I use up too much of my energy or raise my pain level too high, I won’t be able to do some or any of those other things.

The second consideration is the nature of the material itself. Unlike wood, PMMA will begin to melt if it gets too hot. This will deform the piece you’re trying to make and, if you ignore the warning signs of overheating, it can actually discolour the plastic.

To cut PMMA, you need to use friction. Whether you’re using a saw, a grinder, or a sander, the problem remains. You will have to go slowly and give the material adequate time to cool down during the cutting process. You must work in stages and keep moving the tool to different parts of the piece.

The third consideration is the tools themselves. I consider my Bosch multitool to be a decent machine but even it overheats after a few hours of work. It needs time to cool down as well. It’s also possible for the teeth of the tool to get gummed up with melted plastic and it will need to be cleaned.

Vibration from the cutting tools can cause numbness, tingling, and even nerve damage if used for a prolonged period of time. This can be partly mitigated by keeping the cutting bits clean and sharp. The one I’m using needs to be replaced but I’m having difficulty sourcing Bosch starlock cutting bits in Finland. Ah, the joys of living in a remote corner of the world.

Slow and steady; we’ll get there eventually.

New Projects & New Workshop

Oh hey, two new swords in progress! Nice.

Are you ready!? Me neither. Anyway, I have a reasonably functional work space and some materials. On the workbench right now is a wakizashi and a modified Clariel order that was cancelled when the pandemic started.

My workshop is now located on the upper floor of my house. It was going to be in the garage but it turns out that the heating in there doesn’t work and the water pipe freezes every winter. Oh well. The entire outer wall of this room is windows so I have adequate ventilation.

I haven’t been idle during my long hiatus. I’ve studied some new techniques and gotten a couple new tools which I hope will make my job easier and speedier. Here’s a picture of the wakizashi in progress. I’ve drilled guide holes through the material with my drill press who I call Emily, after Emily Post. If you know who that is, you’re officially cool.

Anyway, drilling nice 90 degree holes around the perimeter of the pattern I intend to cut out helps me keep my plunge cutter straight and avoid straying off on an angle that I’ll have to fix later.

You can see that the Clariel, a Seraph Blade inspired by Cassandra Clare’s “Shadowhunters” novel series, was already into the first stage of material removal when the project was cancelled. While it’s sad that the customer had to cancel, the upshot is that I can now do whatever I want with this piece. I’ve never had this kind of freedom before. It’s exciting and terrifying.

Well, let’s see what happens.