I Am Done ✅ Fitting My Sword Handle!

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Join us on an epic journey as we embark on the creation of our most ambitious project yet - the "Griffin" sword! This legendary blade, inspired by the mythical creature, will take approximately 7 months to craft and will be the most intricate and advanced sword I've ever forged. Follow our progress as we meticulously design, forge, and perfect this awe-inspiring sword, and witness the birth of a true masterpiece. Don't miss a single update on this incredible adventure - subscribe now and be a part of the "Griffin" sword's story!
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[@petercarbin2077]

You got a metal sliver in your finger last video next time that happens just go over to the surface grinder turn on the electric magnet and it will pull the sliver right out

[@Adam-ot9lr]

Sounds legit. Of course I imagine laying your finger down the wrong way, sucking it deeper and out the other side.

[@gv100_blitz]

True, but it might also tear the skin a lot more

[@petercarbin2077]

@@gv100_blitz very true but it'll be faster

[@petercarbin2077]

I'm very disabled very homebound long story but I do like watching your show I wish I could go work in the shop again but that will never happen keep on doing what you're doing be nice 2 own one of your knives but that will never happen low income but keep making your shows I enjoy them PS show more your family your brother cameraman everybody else that makes it better

[@Jedi-vz3uo]

Tolong buat pisau yang berwarna warni. Seperti merah kuning hijau biru ungu orange dsb. Atau gabungan berbagai warna seperti pelangi. Aku bosan dengan pisau yang warnanya itu itu saja. Please 🙏🏻

[@ThatWorks]

You are a mad man! That is the oddest way to mount a wheel pommel I have ever seen! Crazy!

[@fettmaneiii4439]

dumb or crazy. Imo just inexperience with swords is all, nothing more.

[@ThatWorks]

@@fettmaneiii4439 not dumb. Solved the issue. Just in a super complex way.

[@Azmodon]

to expand on the agreement of 'the measurement is from kick-out' as you do (is correct), the reason behind it is that the spring holding the tip tends to auto-centre the tip within a few thousandths, and even if it doesn't, by pushing it just past that static seated point you are verifying that you've found the limit of the true edge (repeatably accurate to ~0.001) because once they've "lined up" while spinning, they've only lined up 'by eye', while spinning (shadows / dirt / finger prints can all make you think something's lined up or not when it's doing 1000 rpm). Also if you're centre finding, you're measuring from both sides anyway, so as long as your procedure is the same on both sides it doesn't really matter. You can do it without waiting for kick-out, but that's usually done on softer materials, or where you're measuring up to a finished surface that you don't want to mar (in such a case you don't spin the edge finder, you just walk it in and feel for them to line up by hand / nail, as you'll be able to feel the mating of the barrels, accuracy within 0.0005). (because it always comes up, mech. eng. tech, head of R&D for cutting tool fab)

[@jamessouhleris9593]

Kyle buy yourself a set of reamers if you want accuracy with hole diameters. By drilling 020" smaller and using a reamer to finish the hole you'll have a much more tightly fitting pommel nut

[@TheOneLookGamer]

Love the ClickSpring shout out, it’s the channel that got me into machine work

[@corywarshaw4100]

We need a ClickSpring x Kyle crossover episode!

[@tdg911]

From what I understand the edge finder just as it kicks out is where the reading is taken from. Love the channel and your work is absolutely in a field of its own. Beautiful work as always.

[@Sinrise]

That's what I was always taught as well, by several machinists.

[@Blapsification]

It is the correct way. Reason why is for the sake of repeatability. More specifically mechanical repeatability. The edge finder will always kick out at the same spot, whereas just lining it up to run on center can easily be misjudged.

[@jamessouhleris9593]

Yup that's how they work

[@nickmartian9527]

As a cnc/vmc operator Kyle did it right.

[@paulObriant]

The edge finder is supposed to break from center when it's located (at least that's the way I was taught in school). A good rule of thumb for cutting on machines is to look for straw colored chips. Neat videos! Please keep on making them!

[@KyleRoyerKnives]

If you guys want, check out our membership and learn from me how to make really cool knives. Click the link to save $80 www.learnknifemaking.com/

[@NewMessage]

Jumping spiders are harmless, full of personality, and don't bite... often even when mistreated. Be a good dude. Let it keep the shop pest free.

[@lReb]

The shots of that spider at 29:20 were fantastic, proper cute looking thing!

[@anthonymurphy5410]

Bold jumping spider

[@nathanjones6005]

@@anthonymurphy5410 I think so, looks like one. tricky to tell without seeing the back.

[@newton9837]

you can see the intelligence of the jumping spider in it's eyes.

[@corneneethling2277]

Definitly a jumping spider. The only species that is build like that. And no, they are not poisonous to humans. Do actually also make nice pets

[@ravenmoon1165]

I've never been so nervous watching you perform your magic. You're truly the best! Whomever gets this masterpiece is one lucky soul!

[@makhoe1]

Amazing problem-solving. Loved it.

[@andymcleod439]

You can’t image how excited I was to see this video was 80 minutes long. I could watch Kyle working all day, he’s the absolute master of his craft. Keep ‘em coming please.

[@smedlap8789]

That's awesome you mentioned Clickspring! I am always mesmerized when he turns down parts on the lathe. lol

[@Borestbush]

You're such an inspiring creator. You've kept me going in life and with my knife making for so many years. I just wanted to say thank you for inspiring me and so many others.

[@shotout74]

As a machinist, yes, you are using the edge finder correctly. I'll refrain from talking about the end mills in that keyless drill chuck overly much. Drives me absolutely nuts when you do that. I really enjoy your content nonetheless 😅 Seriously though, appreciate the craftsmanship and creativity of your work. You turn out some amazing work.

[@WHJeffB]

+1 on the end mill in the drill chuck... Mentioned it a few times in his past videos but stopped because it was a waste of time. But seeing as you brought it up! Regarding plunging with the end mill... Drill the through hole a bit undersize, THEN plunge the larger end mill to true up the hole. Also... Super glue/CA is weakest in shear. Turning the OD of the pommel like he was is probably the most side load/shear force you can put on that CA bond. With thin parts in soft material, it's not a big deal. But the steel pommel... He's lucky it didn't break loose. The glue arbor was far too thin for something like he was doing too, but in the end, it worked which I guess is all that matters.

[@toml3806]

Are you using a round die in a hex die stock?

[@ThatOneBlacksmithGuy]

​@@WHJeffB what I don't get is why he wouldn't have tested it with something less valuable first- "here's my last chunk of this steel, I'm gonna go stick it to a lathe in a way that if it breaks off, it's gonna shoot off to space and ruin it"

[@WHJeffB]

@@ThatOneBlacksmithGuy For sure... I hate to nitpick the guy though, he's an incredible craftsman/bladesmith. He and his dad have created so many works of art. I guess I get a little disappointed when Kyle mansplains machining techniques in the videos when it's pretty clear to those of us with machining experience that he's not doing something (so basic) 100% correct. But as a few people pointed out to my previous comments about using end mills in a drill chuck... "It works". For sure it has, but it's like using an adjustable wrench to work on your car, instead of a proper set of open/box end wrenches. It works but it's not right...

[@No1sonuk]

I'm 9:07 in, wondering why he's talking about grinding the faces of the pommel when he could do a good job with a lathe and ball-turning attachment. Though I suppose he probably doesn't have one.

[@Joe___R]

You definitely should buy a good precision lathe. Then buy a quality 3 jaw chuck, 4 jaw chuck, a collet chuck, and a mag chuck. With those four chucks, you can do just about anything. A mag chucks are much safer than relying on ca glue on larger parts like that pommel. You also really should get a couple good sets of drill bits. One set should be solid tungsten carbide drill bits. Then, you should buy additional drill bits in your most commonly used sizes. Even though you can resharpen them, it greatly slows you down if you have to stop and do that.

[@RunTheLoots]

next level everytime. The best blade smith ever. This isn't tiktok, its craftmanship.

[@user-jf5rx2gf8l]

What are you plans for dealing with the hole through the centre of the pommel? you didn't seem too stressed out about it, which makes me think you have a plan. Or you always intended to drill though the centre of the pommel anyway?

[@FuneralProcession]

The pommel is leaking? In the middle? Congratulations, you are the proud father of a girl ❤😂

[@neebatron]

“Why do I keep thinking myself into these bad ideas?!” So we can watch you think your way out of them! Thanks, Royer family. I started watching these years ago for the insane “seeming” perfection of the Damascus patterns. Now that I can watch everything that goes into that “perfection” makes it so much more meaningful. Awesome vids

[@Roninx1980]

You are correct, using an edgefinder you will move it until it kicks out.

[@bobbyboopboop5741]

You should make a double fuller Gaboon Viper sword next. Their beautiful patterns with your Damascus tile style would be mind blowing. Top of the sword the tail of the viper, the hilt as the head. Maybe Fang guards. Just a thought

[@MrDANGEROUSIDEAS]

you are correct Kyle, do you want the center to gust offset and that's perfect

[@BeatsbyLegend]

Kyle....sir....I absolutely LOVE your builds. Checking for updates DAILY, man, lol. I just gotta put in the wish list you do a Katana, but a Kyle Royer style Katana that would put a lot of other people's Katana builds to sleep, lol. I can only imagine what one would look like if YOU did one.

[@ronjennings1453]

I literally check my feed everyday hoping that you have posted a new video! Love everything in this channel

[@toscarsson]

I can probably count the number of times I have commented on KZbin videos on one hand, but Kyle’s work is exceptional! This is one of the rare times I can’t decide if I enjoy the process or product better. That being said, custom work commands a high price, as it should. I would love to see a KR drop-in blade for the CRK Sebenza 31 series. I don’t even care if it is scrap or combined damascus. With the CRK hardware being so consistent and the Sebenza series being so successful, I would think this could be a great way to subsidize the high end custom work, with a semi-custom entry. This would add a Gucci touch to the CRK for those who are already prepared higher end prices for knives, maybe not full custom but starting to dip their toes in the water. Anyway, one can dream! Thanks for what you do Kyle!

[@matthewphillips1728]

Have been following your Journey an love watching you work, your videos are always entertaining an educational, this one seemed different in a good way, keep up the awesome work.

[@dalepr69]

Fyi, that final tool you were using in the mill is specifically for a woodruff key, a semi-circular key

[@streetDAOC]

ITS BEEN ALMOST A MONTH MY BOY!!!!!!!

[@obadiahbird8239]

Hey, machinist here, the way I was taught to use an edge finder is the same way you used it

[@Cliffepoos]

I love you're attention to detail.

[@arvilmaddox6666]

You are correct on how to use the edge finder. Normally I will back off a few thousands once setting my zero then double checking my DRO for zeri

[@wholesome4028]

kyle, as a cnc machinist, you are using the edge finder correctly. the idea is to move it just until it moves off center like you did.

[@jvmiller1995]

I have turned large round pieces that was not even in the jaws. It had a tiny center hole so I just use the pressure of a live center to hold it against the jaws. I bet money you could glue a short 3/4 round to the center and drill a center hole in it for the tailstock to add a little more stability if you need to turn something like that in the future. Amazing what little bit will cause or prevent chatter when turning.

[@mrxxxmiseryg9388]

When drilling always start as small as possible/comfortable as you can go, and don't worry about sparing the oil it's the only protection you have from work hardening. It can get messy but of course a good thick oil can make a difference. Still for what it's worth you pulled it off marvelously. Keep up the great work.

[@anthonymaughan6103]

Magic , man that's crazy great fella , love it 👍

[@ronsimpson143]

Could you rig up an oiler for your mill? You could have a flexible lubricant tube going most of the way, with a stiff wire you could bend leading right to the edge of the end mill. Put a ball valve at the top to control the flow, and it will drip down the wire onto the work and keep you from having to constantly add lube. Just a thought.

[@DjDolHaus86]

When grinding the bevel onto the pommel you could have clamped a backstop onto the work rest to prevent the belt sucking the piece in too far and ensure accuracy of the final depth. Might make your life a bit easier if you do something similar in future

[@IanZainea1990]

24:38 you should be able to use your drill press arbor as a parallel guide for the tap wrech.

[@cyb3rk3v]

Very cool lil jumping spider. Phidippus audax if I’m not mistaken, aka the bold jumping spider.

[@mordredthehero]

Looks like to me. I have a couple I keep as pets! They are very intelligent little things!

[@pinheadlarry9495]

Hey Kyle, would you do a future video on how to sharpen drill bits on a belt grinder?

[@nickd698]

You could use the tail stock with a centre to put that puck in the centre and hold it untill the glue sets.

[@know_me856]

Bring the next part soon, we are waiting

[@user-jf5rx2gf8l]

Love the vids. Its cool to see the project coming together over such a long time. Looking forward to seeing the final result. What are you plans for dealing with the hole through the centre of the pommel? you didn't seem to stressed out about it, which makes me think you have a plan. Or you always intended to drill though the centre of the pommel anyway?

[@theoldbear4213]

The hole on the pommel nut could be used to attach a tassel of some kind. Don't know if that goes with you're design, but it seems like a thing to do. It's not like it's an Irish Ring pommel where the hole is the point, after all.

[@codybruce101]

If you had a four jaw chuck on your lathe vs a three jaw chuck you could indicate the part in to be perfectly on center and that would solve the runout problem when rechecking.

[@imcalledsprite]

Hey Kyle, I have a crazy suggestion. I asked ChatGPT what the best alloy would be for a longsword (1m blade) exhibiting exceptional hardness, strength (resistance to shattering and plastic deformation), being lightweight and corrosion resistant (cost absolutely not a concern). The suggested alloy (by weights): Tungsten Carbide, 65%, Titanium, 20%, Vanadium, 10%, Chromium, 5%. Given the exceptional quality of your pieces, why not pioneer an exceptional alloy?

[@SH1974]

10:22 it does not really matter if You doin' it that way or the other - as long as You do it always on both touches the same way, the reading in between the 2 points will be the same. Same if You use a stripe of paper to touch both sides directly with the cutting tool: it doesn't matter if the used paper is thick or thin (or how thick it really is) - as long as You use the same paper for both sides of the touch, the "unknown factor" of the paper will compensate itself.

[@Curtislow2]

You could have sandwiched the pommel with round block of wood held in place by the tail stock to hold the pommel and mitigate the part flying.

[@jimcorbett3764]

I love the shape of the pommel- the polished look is awesome, but I really want to see the etch on the finished product.

[@KyleRoyerKnives]

I hope we can etch it within 4 months!

[@ronsimpson143]

Found this on the interwebs about your spider friend. The bold jumping spider (Phidippus audax) is a common spider in North America that has large, iridescent green or metallic-blue fangs. Their prey includes flies, boll weevils, tobacco budworms, bollworms, and leafworms. Bold jumping spiders can make great pets, but they require proper care and attention like any other animal. No, jumping spiders are not poisonous. Despite their less-than-appealing appearance, jumping spiders are not dangerous to humans. That said, they do have fangs capable of producing venom. Some individuals may have allergic reactions to a jumping spider bite, causing dizziness, nausea, or vomiting.

[@thomasbecker9676]

If you're getting those super-stringy chips, you should increase your spindle speed and/or feedrate.

[@ughmas]

Incredible up close shots from Josh! your videos are on another level now... curious what your plan is for the "oil hole".. is that just going to be filled in with gold inlay?

[@JS_Precision]

I honestly thought you were joking about the glue trick in the lathe.. never seen that before. Crazy how strong modern glues are.

[@lesliecompton4061]

4 jaw chuck and clock it or soft jaws machined to suit, perhaps just proper coolant not tapping oil will stop the work hardening, then you will with practice get very nice finishes and less work, and think of using a running center on the tail stock to support the workpiece

[@actorartistmusician]

Long time listener…first time caller. Love your work - and the whole vibe of your channel. Just a weird question/observation. When you went to turn the pommel nut on the milling machine - It looked almost like the shavings coming off your pommel nut were covered in Dye-Chem but also had gold in them - but there was no dye-chem on the piece…is that because the heat generated from shaving the metal is actually turning the Shavings gold and blue - kind of like when you’ve used a torch to heat-treat or soften a spine or a tang in other videos? I know totally random…but new to me. Keep up the amazing work. I get to forge vicariously through watching these videos. Cheers Royer Fam!!

[@Shadowmaster68]

Huge fan of both you and @clickspring. You both have incredible attention to detail and perfection! Looking amazing as always!

[@PokeRemcards]

Your edge finder needs to be replaced, they are relatively cheap and when you get a new one, you will see the 'pop' a lot more clearly. Because yours has some play you are seeing it act that way, you are absolutely spot on about nudging it forward .0001 thou at a time until it clearly breaks evenness. Also, you want less contact on the head of the edge finder to the part, the more contact you have wears the tool out quicker which is why i think you have the slight wobble after you have hit the edge of the part instead of the obvious wobble you should be seeing. Note: the ball style wigglers/edge finders are even easier to see the pop.

[@thomasbecker9676]

I prefer the wiggler myself.

[@gieldenhertog]

might be a good idea to get a drill speed chart because from my experience such a small it should spin way faster. about 12 years ago i did a internship at a metal shop and was drilling 30mm holes with a faster turn speed then that and the chips where blue from the heat. so this is way to slow even for carbon steel and it should not make that terrible noise 😉 added note if your hole is triangular it has probably some thing to do with how you sharpened the bit i had that happen a lot when i was learning i used to drill a ton of holes in scrap metal to get it right. i have never seen split tip on such small bits though i only did it on 15mm and up biggest bit i sharpened was wider then the sharpening stone back in my high school days🤪

[@osdanicorcho3024]

Saludos desde Cuba

[@davelewis6093]

Balance !!! is what a true swordsmen cares about

[@bartroberts1514]

Curious how you establish your speeds and feeds for these materials?

[@MakewithJosh]

Great progress! Would be cool if you did a collab with a guitar maker, i.e. damascus bridge, tuning pegs, ferrels, maybe even a scratch plate, etc.

[@TrevorDennis100]

I love that you are a fan of Chris at Clickspring, although we shouldn't be surprised. You could improve how well the pommel was mounted by pushing the tailstock against it. You wouldn't want the live centre digging into it of course, but if you had an intermediate disk that was thick enough to be centre-drilled, and CA glued that disk to the pommel, you'd have both lateral and torsional support.

[@TrevorDennis100]

The first two years of my toolmaker apprenticeship were at the Ford Apprentice Training School at Harrold Hill in Essex UK. During that time they bussed us to a safety museum in London where saw some horrific pictures. One that has stayed with me was a finger, with 12" of tendon and muscle, that had been ripped off someone's hand while they were polishing a shaft on a lathe. They had had emery rapped round the shaft, and around the finger for good purchase, and the emery cloth had gripped the shaft and wrenched the finger out of his hand. Gruesome, but it did the trick.

[@TrevorDennis100]

BTW,, I have stopped at 11:06 when it looks like you are about to drill into the pommel with an end mill. You need a slot drill to do that. They are usually two fluted to the end mill's four flutes. It looks like it worked OK though. Did that end mill have a recess in it's centre, or cutting edge right across?

[@No1sonuk]

@@TrevorDennis100 Yeah. I'd go with the twist drills first, than maybe use an end mill as a reamer.

[@michaelmorrison4843]

If people were to watch all these vids of the making of this sword, they would understand why it is so expensive! And they would appreciate all the time and precision that goes into making it! 🤔😱😁

[@paullmight42]

I have to imagine Kyle checked the orientation of the pattern on the pommel before drilling the hole bc he has such insane attention to detail...but i sure was worried about it the whole time bc he did not mention it haha...

[@stillraven9415]

Most take it like you to the point it kicks out, however if you're looking to find the center the only thing important is you go to the same point on each side.

[@griffithshandmade-knives]

I have to ask, was a replacement 1/4” cobalt bit going to take that long to get? Seems not ordering one caused way more stress.

[@jvmiller1995]

edge finding you take the reading just as soon as it walks to one side. Like you are doing. Or that is how I was taught when taking machine tooling classes in the 90's

[@pranavalfredmarandi8724]

Hey man, I have watched most of your videos and which are very interesting and a nice learning point for me. Why not challenge yourself with something new, I saw you never made a Japanese Katana, why not try something like that it would be a nice learning experience for you and an interesting video too.

[@Flying0Dismount]

Weld flaw in the pommel.. This is why mosaic is so hard.. So many welds, so many chances for just one to not work and you can't just flux and hammer some more like regular Damascus as you can't distort the pattern..

[@newton9837]

inlay gold into the hole in the pomel to fill/hide it?

[@_o_]

oh my god here we are, Friday evening, just got off work, and here we are finishing the Griffin Sword!!!!

Maybe you wanna buy some high quality carbide bits for those holes in very hard steel, they are fragile but cut much better

[@motaman8074]

OUTSTANDING!!!

[@otter1959]

Could you show us how you balance a sword or dagger please?

[@WavingWorld]

How did we ever manage to craft metal like this before heavy machinery?

[@BottleOfCoke]

By not achieving the same results.

[@trentgay3437]

1/4 to 1/2 turn and break the chip with a little backwards twist is exactly how i was taught to tap.

[@ronbuckner8179]

You need to get some bolts with larger heads so they’ll lock inside that table

[@gameface8080]

I already can’t wait for the next video.

[@self_taught_stuff]

57:05 that's one thing that I want to learn how to do when I design parts for 3D printing, how to position the thread to get the perfect orientation of the part when its screwed tightly. maybe I am using the wrong software, I design my parts in SolidWorks 57:22 is that a crack on the pummel on the right face?

[@user-vn6hi2bi3g]

Actually it's within .002" of being centered, more accurate than any sword ever made. Great work! Ray Stormont

[@gragreiser1501]

I was hoping to get more footage of that jumping spider (Phidippus audax aka bold jumping spider) when I saw him in the background of the "day 56" screen. Smart little critters and pretty much harmless to humans.

[@Bevel_and_Bark]

Love the channel wish I could start forging

[@davedeboy5726]

can't wait for you to turn this and finish the handle.

[@justineseman3741]

Kyle not Recording the Final pieces in 4k is a disservice to his work.

[@Sarogus]

Just wondering how long will the Griffin shirt be on sale for? I don't want to miss out!

[@eclipse12822]

A lot of people say Jumping Spiders are the puppies of the spider world. Super cute and inquisitive

[@jamiewoodard2380]

When using an edge-finder (or "wobbler"), run it in until it kicks the tip out of center. That's where you set your datum. If the tip is .2", you'll set zero at =/- .1" in whichever axis you're setting up. Also, have fun tramming your mill back in after breaking the head loose. 😆

[@loiblanche5863]

I'm a polymechaninc and to confirm 10:26 yes that is the right way it has to go till it moves to the side. And i don't understant why you coulden't just put the pamul in the chuk instead of gluing it. Can you pleas explaine?

[@IanZainea1990]

My guess was so that he could do it all in one pass. Instead of flipping the part

[@loiblanche5863]

@IanZainea1990 yes i also think that was it. It's just a strange technique

[@michaelchesney1271]

Stop when off center. Easier way is to use dial indicator around the out side of the piece. When all measurements are equal that's absolute center.

[@codybruce101]

As a machinist you stop when the edge finder breaks. When it goes out whack as you say.

[@justineseman3741]

Recording the cut in the reflection of the Mirror was a SLICK Fucking idea by Josh @40:40

[@otter1959]

Use the hole in the center to set a stone!

[@REKKnives]

I was laughing on the pommel nut drilling... Seems like that's the life of a knifemaker, constant trouble shooting one problem to the next. I'm right there with ya Kyle most days!

[@MarvinConman]

Haha, I use my drill press as a makeshift lathe too XD

[@grizzly6871]

Love your shows

[@SethK1]

Machinist, You're right, when it kicks over.

[@stepheather1]

What's the brand name of your milling Machine and model #?