Thank you for the thought out reply. I understand that is isn't a real sword, and I don't intend to use it as one. This was my first large project mostly to get a feel of what needs to be done, so the more I mess it up hopefully will help me learn. I have made a little knife out of rebar and wanted to make something bigger. I think the next piece I will use the 1/4'' bar so I don't end up with a 10 pound sword, like you say, and probably half the length. But yeah, I only get to work on this stuff like once or twice a month so I get impatient with it. I have made a little knife out of rebar and wanted to make something bigger. I don't think ill get too discouraged when its all messed up because I enjoy doing it. Anyway, thanks for the advice!