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Pattern Welded Spear from Spear Class at NESM

Emiliano Carrillo

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Hey everyone!


I taught a class at the New England School of Metalwork over the last week and thought I would share some images here! I took a ton of photos over the class, but will kind of pair it down to the images of the demo spear I made, and a few shots of all of the spears together. 



We studied and made three pattern welded billets based on historical patterns seen on various originals. 



We also drew out a bunch of wrought iron sheet from round stock for the sockets. 



We also made some really nice edge steel, 480 layers of 15n20 and 1095



The wrought iron sheet with the templates ready for cutting.



A few of the twist bars for my spear, 24 twists on the left, and one of the interrupted twists for the other side of the spear. 



Beginning to square the twist bars to assemble the spear. 



5 bars welded into one! I like to do my welding sequences as close together as possible. I laid the twist bars and wrought iron core together, and forge welded the five bars in the same step. 



A quick, and apparently out of focus, test etch of the side of the spear with the interrupted twists in it. 



The edge bar has been wrapped around the core and forge welded in place, then drawn out! 



Test etch on the other side of the spear. 



Wrought iron socket ready for forge welding. 



The plan!



And the result! Next to the demo I made in preparation for the class. 



Something kind of interesting! I left my spear thick to account for grinding into the center of my pattern and to avoid drawing it out too long. I am a big fan of complex multibar patterns, and this was a fun exercise in making precise patterns in a different blade shape than what I'm usually doing. 



The finish ground weight! This was after hardening and tempering of course. 




And here's the finished piece! Made from 7 separate parts, an iron core, 4 twist bars, a wrapped around edge, and the socket! The twists are 11 layers of 1095 and 15n20 and the edge is 480 layers of the same. It was finished by being put on a 7 foot Ash haft, and its kind of amazing to hold something this alive on a 7 foot pole! We're in the process of figuring out where to display it in the shop now!


























And a shot of all of the spears finished during the week! All have different patterns and constructions and showcase each students creativity beautifully! I'm super proud of the work these guys did, and will share a shot of all of us together in a bit. I don't think I've ever seen this many newly made spears in one place, and much less of this quality! 






Edited by Emiliano Carrillo
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Impressive to say the least. Something primal about the spear that calls to the inner self. 

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Von Gruff


The ability to do comes with doing.



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Awesome stuff Emiliano. That’s some good work all around. Well done with the class.

"The way we win matters" (Ender Wiggins) Orson Scott Card


Nos, qui libertate donati sumus, nes cimus quid constet.

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What they said!  :lol:


And yes, there is a real moment of awe when you first haft a spear and it comes alive. You suddenly realize just how dangerous they are.  Totally different feeling from when a sword first wakes up...:ph34r:

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Little late to the post but I love reading this.  I will be taking notes and hitting the forge soon to make my own :). Thanks Emiliano! A true help and guide as always! 

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