From Bearing Cylinders to Blade: Forging a One-Handed Zweihander-Style Sword
The art of transforming scrap metal into a majestic weapon is not just a craft—it's an epic journey of fire, hammer, sweat, and vision. In this forging adventure, we take something ordinary—bearing cylinders—and reshape them into a compact yet powerful Zweihander-style sword that you can wield with just one hand.
This is a one-of-a-kind metalworking story filled with intense heat, dramatic sparks, and the kind of focused craftsmanship that brings steel to life. Whether you're a bladesmith, a fan of functional fantasy weapons, or just love watching glowing metal take form, this project is a masterclass in transformation.
Join us from the first spark to the final reveal, as we take you through every exciting phase of this build.
🔥 1. The Introduction: From Scrap to Legend
The story begins with a collection of old bearing cylinders—tough, hardened steel rings salvaged from industrial machinery. Most people see them as scrap. We see them as potential.
Our goal: Forge a compact one-handed Zweihander-style sword. Traditionally, a Zweihander is a massive two-handed sword, but this unique version will be scaled down, keeping the iconic look—wide blade, long fuller, crossguard—but crafted for agility and single-hand use.
To pull this off, we’ll need extreme heat, top-tier grinding, patient shaping, and forged-in fire-level craftsmanship.
🔨 2. Forging Begins: The Fire is Lit
We start by stacking and welding multiple bearing cylinders together. The steel in these bearings is high in carbon—perfect for knife or sword making but extremely tough to work with.
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The cylinders are cleaned and stacked tightly.
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The forge roars to life, heating the metal to over 2,200°F (1,200°C).
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Sparks fly as the steel glows bright orange.
Using a power hammer, we start flattening the welded stack into a single billet. This is the base of our blade—the blank canvas.
Each hammer strike spreads the layers, fusing them into one. The billet is drawn out into a bar approximately 18 inches long and 2 inches wide.
⚙️ 3. First Rough Grinding: The Sword Emerges
After the billet cools slightly, it's time for rough grinding. Using a 2x72 belt grinder, we shape the basic outline of the blade.
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The tip is tapered.
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The profile is drawn to resemble a classic Zweihander: straight edges, slight taper, and a strong central spine.
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Rough bevels are ground in—nothing precise yet, just shaping.
At this stage, it looks more like a big kitchen knife than a medieval weapon. But don’t worry—this sword’s soul is still forming.
🔥 4. Second Forging Session: Heat Returns
Back to the forge.
Now, we work the spine and bevels more precisely. The metal is repeatedly heated and hammered by hand. This is where the character of the sword begins to show.
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The fuller groove is hammered in with a spring fuller tool.
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The blade is stretched to over 24 inches.
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The tang is forged to accommodate a hidden tang handle style.
At this point, the sword has weight, symmetry, and a clear silhouette. It’s no longer just steel—it’s a weapon in the making.
🗡️ 5. More Shaping and Grinding: Refining the Beast
Back on the grinder, we refine the shape even more.
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The fuller is ground and cleaned.
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The bevels are evened out.
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The edge is thinned down but left slightly thick for later heat treatment.
The grinding process takes hours. This is the dirty, dusty, noisy part that most people skip, but it’s critical. Every pass of the grinder sharpens the sword’s identity.
The steel, now cool, reflects light along its edges—an early promise of the finished blade.
🔨 6. Final Forging Touches: Straightening and Tweaks
With the shape nearly perfect, it’s back to the forge one last time for:
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Straightening the spine and tip.
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Correcting warps or twists.
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Ensuring the tang and blade are in line.
These finishing touches are crucial. A beautiful sword with poor balance or crooked geometry won’t perform.
The heat helps relax the steel, allowing small corrections that aren’t possible once it's fully hardened.
⚔️ 7. Last Grinding Pass: Sharpening Perfection
Now it’s time to bring out the blade’s true face.
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The final bevels are ground.
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The spine is polished.
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The fuller groove is smoothed and rounded.
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The edge is brought close to final sharpness—but not quite sharpened yet (because heat treating comes next).
With the help of progressively finer belts, the sword transforms from a dull gray chunk to a sleek, shimmering weapon.
You can see the grain of the steel, the fine lines of the grind, and the flawless symmetry. It’s forged beauty.
🔥 8. Sword on Fire: Heat Treatment
One of the most intense moments of the project.
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The blade is normalized three times to relieve internal stresses.
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Then it's heated to critical temperature (about 1,500°F).
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It’s plunged into oil in a dramatic quench—a flash of fire and smoke erupts!
If done right, the sword becomes hard as a file—but also brittle.
Next, it goes into the oven at 400°F for two hours—twice. This process, called tempering, restores toughness while maintaining hardness.
The result? A battle-ready blade.
🛡️ 9. Guard Making: Building the Crossguard
A Zweihander is known for its dramatic crossguard.
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We use mild steel to forge a straight crossguard about 8 inches wide.
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It’s forged to curve ever so slightly forward.
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The center is filed to perfectly fit the tang.
The guard is heat-blued for contrast—a dark steel tone that highlights the brighter blade. It's then pinned and epoxied in place.
The sword is now looking like a proper piece of history—part fantasy, part function.
🪵 10. Handle Crafting: Grip of a Warrior
We use seasoned walnut wood slabs to craft the handle:
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The handle is shaped to fit snug over the tang.
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Brass spacers are added for flair.
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It’s epoxied, clamped, and then hand-shaped with rasps and files.
The grip is slim, contoured, and wrapped in black leather cord for extra hold. We finish it with linseed oil for shine and protection.
Balanced perfectly, the sword can now be wielded one-handed, despite its impressive size.
🎬 11. Final Reveal: The Result
The transformation is complete.
From scrap bearing cylinders to a sleek, functional, one-handed Zweihander-style sword, the result is nothing short of stunning.
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Blade Length: ~24 inches
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Handle Length: ~5.5 inches
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Overall Weight: ~2.3 lbs
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Balance Point: ~4 inches from guard
The sword gleams under light. The fuller is bold. The edge is sharp. The guard and grip bring it all together into a blade that looks ready for the battlefield—or your wall.
Every inch screams craftsmanship. It’s not just a blade—it’s a legacy in steel.
🧠 Why It Matters: Forging is More Than Metal
This project proves that even industrial scrap has a story to tell—if forged with heart and skill.
Turning bearing steel into a custom, hand-forged weapon requires more than tools. It demands:
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Vision to see what others don’t
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Skill to control fire and metal
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Patience to grind, shape, and perfect
It’s also a tribute to history. The Zweihander was once wielded by German mercenaries in the 16th century. We’ve revived that legacy—on a scale that fits today’s hand and heart.
🎥 Watch the Build on YouTube
If this article sparked your interest, you’ll love seeing the sparks fly in real time. Visit our Adventure Blade YouTube Channel for the full video breakdown—from molten steel to finished sword.
You’ll see every forge fire, every grinder pass, and the moment the sword is quenched in flame.
🛒 Get Custom Leather Sheaths at KamalLeather.com
Looking to pair your custom blade with a handcrafted sheath?
Check out our leather knife and sword sheaths at KamalLeather.com — all handmade in the USA, using full-grain vegetable-tanned leather. Every sheath is stitched with care and built for real use, whether you're carrying into the woods or onto the stage.
⚔️ Final Thoughts
This forging project isn’t just about making a weapon. It’s about resurrecting the past, respecting the steel, and pouring soul into every step.
From rusty bearings to gleaming blade, this sword now tells a story—and it’s ready to join yours.
Want more projects like this? Follow Adventure Blade on YouTube, and let’s keep the forge burning.
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