Here's How to Make Your Very Own 40K-inspired Chainsword

If you are a fan of the Warhammer 40K Universe, then we have a very real treat for you today. Using some basic components, you too can make your own, working, chainsword!

Follow this simple guide to find out how. 

But first, you'll some materials and gear to get the job done. 

The best picks that will help you do the job

• Bike chains
• Angled gearbox
• Motor axle sprockets
• Motor/old power drill
• Ball bearings
• Metal tubing
• Steel sheet
• Lathe
• CO-Z Stepper drill bit
• Dekopro welding gear and safety equipment
• Various nuts and bolts
• Basic tools (wrench, screwdrivers, etc)
• Evolve sépray paints

Optional

• A tech priest to bless the piece
• A suit of power armor
• Some daemons to purge

With all your tools and materials in hand, it is now time to get on with this awesome build.

Step 1: Make the main chain mechanism

The first step is to modify one of the sprockets, if needed, to fit the gearbox for your chainsword. You may need to augment the eye of the sprocket and weld some smaller metal discs to achieve this. 

Watch the video for more details. 

Once done, affix the sprocket to the gearbox as shown. With that complete, make a pulley wheel using a suitable material to wrap the chain around to make the main chain drive for the sword. 

Use your lathe once again to do this. Add ball bearings to the middle of the pulley, a thread a short length steel rod through it to act as an axle. 

With that done, connect your lengths of bike chain together to form a continuous loop from the drive sprocket and the pulley wheel. You will also need to fashion some lengths of steel bar to connect eh pulley to the main shaft of what will become the completed sword. 

Step 2: Form the main sword shaft

With the main mechanism for the chainsword basically complete, we can now move on to building the main blade shaft. Measure out and cut a length of tubular steel to the length needed to make the chain loop taught. 

Using a stepper drill bit, drill a series of holes in the tube so that the pulley can be mounted to the shaft. Mount the pieces together using washers, bolts, and nuts as needed. 

With that done, bolt or weld the other end of the tubular steel to the main chainsword gearbox. Once done, sketch out the shape of the teeth of the chainsword to your own design. 

Once happy, transfer the design to some lengths of steel sheet and cut out as needed. Weld these teeth into place along the length of the bike chain as needed. 

Once done, carefully give the chain a test run. Make sure you keep your fingers and arms well out of the way!

Step 3: Make the hilt of the chainsword and guide rails for the chain

Next, make some thin lengths of t-shaped tubular steel to act as guides or runners for the chain. Weld to the main shaft as needed. 

Next, cut some lengths of more tubular steel, and weld the pieces together to make a hilt for the sword. Weld this into place on the gearbox as needed. You may want the main handle to be made from a length of steel rod, for example.

With that done, begin to build up the main blade of the chainsword with lengths of steel sheet. Weld into place as needed. 

Step 4: Design and create the decorative parts of the sword

Next, either create by hand or 3D print various decorative features to give the chainsword the look of a brutal futuristic weapon. You can keep the design as "pure" to the 40K Universe as you like, or not. 

Once all the pieces are ready, glue, bolt, or weld them into place on the piece. You can make panels for the main blade using some plastic-card too. 

With that done, connect the modified drill motor to the gearbox, and close it up using any housing pieces you've created. 

Once you are happy, paint the entire piece as desired. Add any other details you then want, like wear and tear or decals, purity seals, etc. 

Your genuine working chainsword is now ready to purge some of the many enemies of mankind. For the Emperor!

If you enjoyed this little project, you may enjoy some more weapon-related projects? How about, for example, making a slingshot from an old piston?