Pattern Welded Spear from Spear Class at NESM

[Emiliano Carrillo]

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 February 14, 2022 by Emiliano Carrillo

[clint c]

That's a great outline of the process, very impressive work by you and your students! Clint

[Francis Gastellu]

Such beautiful pieces. Thank you for sharing the photos and the process, it is really inspiring! 

[Garry Keown]

Impressive to say the least. Something primal about the spear that calls to the inner self. 

[Charles dP]

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

[Alan Longmire]

What they said!  

 

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...

[Gilbert McCann]

That turned out great. I love the combination of bars.

[Jirka Antes]

So clean work and nice, fine pattern, splendid !

[Doug Webster]

Thanks for posting.  NESM has been on my bucket list.   Interrupted twist is really interesting.

[Dan Hertzson]

I really was hoping to get to this class, but couldn't get time off from work.  Fantastic results.  Any chance you would consider teaching it again (possibly in Rochester, NY at Arc and Flame?

[billyO]

Nice!  Looks like a fun week.

[Jonathanbradshaw]

This looks like a great class. I second Dan in saying I would go to this class if it was done at NY arc and flame center, or Adirondack Folk School

[Doug Webster]

Stupid question.   What are the tools hanging on the steel rail in the photo labeled, "the plan"?

 

 

[peter fontenla]

But what beautiful things!!!, thanks for sharing Emiliano!!!! how I want to be there!!! a hug

[J.Arthur Loose]

Had I known and been able I would have done this one. Noice!

[Coulton Cline]

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!