How to Make Rapper Swords – summary

On 12 December 2020, the Morris Federation hosted a Zoom presentation by Frank Lee, an experienced craftsman specialising in rapper sword making since 1977. The talk offered an informative overview of the processes involved in crafting these intricate performance tools, from creating swivel handles to assembling the final product.

Frank began by focusing on the construction of swivel handles, a key feature of rapper swords. Using a block of wood, he demonstrated shaping it into a cylinder, drilling precise holes, and attaching ferrules and bearings. He highlighted the importance of accuracy at each stage, achieved with tools such as marking gauges, lathes, and bandsaws.

The discussion then moved to the metalworking aspects, showcasing Frank’s innovative use of repurposed materials. He shared how he constructed his forge using a lorry brake drum and a school fish fryer. Frank demonstrated forging bolsters, welding their components, and drilling precise assembly holes. He emphasised the need for durability in these parts and recounted creative approaches to sourcing materials and adapting tools, such as using Land Rover bearings for making punches.

Frank also outlined the production of blades, crafted from coiled spring steel. He explained the challenges of working with this material, including keeping it flat and cutting it safely. Key steps included softening specific areas for drilling and riveting, with precision maintained through careful heating and clamping. Polishing the blades required the use of progressively finer grades of abrasive paper to achieve a smooth finish.

For fixed handles, Frank demonstrated the use of durable woods like elm. He explained the process of drilling and counterboring holes to assemble lightweight yet robust handles. The creation of bearings and spacers was also detailed, with Frank using a lathe to ensure exact specifications. Throughout, he stressed the importance of quality and reliability, marking each completed sword with his name as a personal guarantee.

The final assembly process brought together all the components. Frank showed how he fitted handles and blades, attached ferrules, and made final adjustments using jigs for consistency. Completed swords were polished and rigorously inspected before being sent to customers.

Frank concluded by reflecting on his diverse customer base, which includes performers from the UK, North America, and Europe. His talk highlighted not just the technical aspects of sword making but also the dedication, skill, and resourcefulness required to meet the demands of this specialised craft.