History

Secrets of a workshop making swords for the UK Armed Forces

For more than 200 years, Wilkinson Sword – best known as the razor firm – made swords for the military but, in 2005, the firm decided to shut up shop.

Former customer Robert Pooley, who was 70 at the time, decided to acquire the company's sword designs and have a go himself.

Now aged 87, his company makes and renovates swords for the Royal Family, dignitaries and militaries all over the world.

Watch: Why you can't draw a sword from behind your back.

He invited Forces News to take an exclusive peek inside Pooley Sword's workshop.

Now, from his workshop down by the sea, his team of sword-makers craft the country's only homegrown swords.

The steel comes from Sheffield and, once ground into its sword shape, it is sent to Shoreham-by-Sea, West Sussex.

Watch: How the pH level of some people's skin can rust blades.

Once they have been ground back and polished, the swords are etched – designed by a computer before being printed onto the blade using roofing felt.

Acid is then poured over which dissolves a layer of the metal in all areas not protected by the roofing felt which is then washed off with white spirit, leaving the design clearly visible.

The accouterments are then assembled and added to the sword.

As well as the British Forces, his swords have gone all over the world and he still flies out himself to Australia and New Zealand to present them.

Watch: Why sword handles are made out of fish skin.

Things you might not know about swords

Some people can rust the blade of a sword simply by touching it, depending on an individual's pH level.
The handle of swords can be made from fish skin, usually a type of ray.
Standard swords are all the same length, regardless of the wielder's height. However, the RAF does make a sword that is three inches shorter - known as 'the ladies sword'.
You can't actually draw a sword from behind your back, as seen in the movies, as the blade is too long.