Arts & Culture

From jewelry to sword, a dream come true

The "Seven Star Sword" with its supreme design arouses memories of the chivalric act. (Courtesy of Chen Yuan-fan)

• Publication Date：05/01/2008
• By  Sandra Shih

After checking with the security guard on the ground floor, the two guests were ushered in to visit their friend living in the building. The elevator required a card to function, so they imagined the apartments inside must be luxurious with expensive interior designs, but the door opened on the 10th floor to a very bizarre scene. The first thing that came to sight was a meter-long contraption used to polish pieces of metal. And instead of a sofa and table, the occupant had furnished his two small rooms with metalworking machines and tools. He was not producing electronic products, but double-edged swords valued at US$10,000.

"From start to finish, I fashion the whole sword, including the blade, hilt and sheath," Chen Yuan-fan said April 3, whose unique works make him stand out from other master sword-makers. Even though most craftsmen outsource the labor-intensive part of the sword production process--such as striking or inlay--to save on costs, Chen insisted on completing every step himself. This guaranteed not only a high standard of workmanship, but ensured that each sword remained a signature piece.

Chen's painstaking efforts paid off during the recent exhibition "Modern knives and swords, beauty of art" at the Culture Affairs Bureau in Taichung City, Central Taiwan from March 29 to April 13. The collectors of cutlery, fighting knives and swords had the chance to inspect his handmade work, such as traditional Chinese imperial swords, Japanese samurai swords, Roman era swords and daggers inspired by medieval fantasy.

"Making swords is more a fulfillment of my childhood dream than a job," the master said with smiling eyes, revealing his pursuit of a dream where the brave hero wore a long sword on his belt when going out to perform chivalrous deeds. Chen has been a fan of martial arts since he was young--especially defensive fencing and the swords used in the sport. The young man admired the justice and bravery of medieval knights, but never thought of living out his shining dreams, or possessing such valuable accessories that protected the lives of his armored heroes.

But life for the master sword-maker did not always revolve around doing something he loved. To reach this point in life, Chen first had to endure a long and winding road that saw him try his hand at several different trades. This began with being taken to a wood shop to learn carpentry by his cousin. After that, training at the Fu-Hsin Trade and Arts School enabled him to pick up the trade of metalwork and work as an apprentice at a metal processing factory by day while studying at night. All these experiences prepared him to step into a promising future in the jewelry-processing industry after graduation. "Jewels are multi-dimensional and not just a flat surface, so a unique design can increase the value of rare jewelry."

A diamond inlayed on a platinum ring attracts the eye of almost any woman, tempting them to take a second look and loosen their purse strings. And the master's skilled hands contained more than enough power so as to double or even triple the value of the jewelry he worked on. "I supply many jewelry stores along Zhongxiao East Road," Chen said, referring to the busiest downtown shopping area of Taipei. In fact, he was so successful that his wife needed to help him count the wads of cash stuffed into sacks every day after they finished delivering his goods to the retail stores. But big profits usually went hand-in-hand with high risk. "Many artisans in the jewelry industry suffered great loss from finishing technicians who sometimes stole the finished products and absconded," he said. Chen thus tried to keep the final steps of processing in-house to minimize such risk, but admitted this was still hard to avoid. One time, jewelry worth several million dollars disappeared overnight and the loss nearly put him in the poor house, he recalled.

The specter of financial ruin discouraged him from persisting in this business and it was not until he found a broken samurai sword on the street that his interest in swords was rekindled. "Originally, I didn't look upon swords very seriously. They were something to indulge in during my leisure time," he said. "Since I like swords immensely, I could engage in the pastime without financial concern or risk."

Chen thus set about sharpening the samurai sword's dull blade and scrubbing away at its stains until the original sheen was restored. Even though he was not making a brand new sword, it still took him three years for the restoration work to be completed and a new sword to emerge from the wreckage. This lengthy process was not in vain though. Seizing the opportunity, Chen was carried back to the world of shining blades again and again, learning more about sword making by reading relevant publications.

"Originally, I started fixing people's broken knives and swords as an amateur, but in the year 2000, I moved the whole family to Taichung and went professional," he said, explaining the turning point in his life when he decided to leave the jewelry business behind. With great humility, Chen attributed his newfound success to his wife. "I was very lucky that she supported me financially through the difficult early times."

Chen's insistence on quality made large-scale production impossible, with his handmade swords usually taking a couple of months to finish depending on the size and length of the rapier. On average, five to eight blades were forged in his hands a year.

If one takes a closer look, the long blade of the samurai sword does not look very sharp, but the cutting force was beyond most people's imagination. When people looked at the blade, they had to remind themselves not to be fooled by its shining surface. The sword, which stretches to 98 centimeters in length and weighs two kilograms, requires two hands to raise it because of the solid substance and structure of the metal. "Don't take this sword lightly," Chen joked. "You can chop off an enemy's head with one swipe." He then made a comparison with a cooking knife used in the kitchen. "See, the blade of this knife is usually thick, while the more dangerous type possesses a thinner cutting edge."

To make the sword more user-friendly became Chen's mission in life and this process began with shaping the hilt. For the master sword-maker, not only the material used to craft the handle, but also its design influenced the weapon's control. To prove this point, Chen reached into a drawer and took out a bowie-style knife. Its grip appeared to be acrylic with a waxed gloss and hardened steel finish. Were it not for the brown color and curved lines, you could hardly believe it was actually made of yew, an evergreen tree or shrub found in Asia and Europe. Although, the wood dried without much luster, after polishing, it appeared bright and felt incredibly smooth to the touch.

Chen believes that finding the correct material to make a handle truly is the secret to successful sword making. "Two small pieces of yew for the handle of one sword I made cost around US$200," he said, adding that he often purchased materials from abroad. "Suitable wood often grows in extreme climates, like scorching deserts and frigid zones. That's why it is so expensive to buy."

Turning raw pieces of wood into finished products ready for use in swords was a time-consuming process. To make the surface smooth and flat, Chen started polishing with heavy-grade sandpaper, dropping back through the finer-grades until the texture felt as smooth as a baby's bottom. "When you see a flat surface, it may not be even, but after you touch it, the hand could easily tell whether there are any extrusions or not."

After finishing a blade, Chen made it a policy to invite the owner to come and try out the sword before taking it home. "The best clothes are tailored and fit the individual figure, and since the strength of a grip differs between people, I always modify the shape of the hilts to suit the size of someone's hand." In his opinion, a sword is one of the most personal items you can own and everyone should possess a unique blade that reflects their personality.

Write to Sandra Shih at sandrashih@mail.gio.gov.tw