Disclaimers and warnings: See chapter 1.

Many thanks to rascalflattsgurl43 for the speedy and accurate beta on this story

Chapter 10 Never give a sword to a man who can't dance.

At four in the morning they were both exhausted and sick of facts about the creatures that didn't get them any further. Dean got up and stretched his back pacing around the room thinking out loud.
"You know we could take two thin tempered steel sword blades and put a thin layer of those volcanic rock strips in between and heat the metal up and fuse it together like blacksmiths do. It's called forge welding."
"You think it would work?"
"I'm thinkin' it would be nice if we could just pierce the skin with a blade on fire and set the Barbegazi free but what are the chances of it never being possessed again."
"Unfortunately pretty low or it would never have been taken over in the first place. It has a pretty easy going nature normally."
"Be nice to send it back where it came from but maybe it means something different when it asks to be free." Dean mused.
"It sees being dead better than being possessed?"
"Might do. The Demagogen is making it do things it detests."
"I guess. So this blade? You think you can do it?"

Sam doubted they could get someone to do it for them and they did have all the required parts. They had packed heavy on the weapons side of things so they had more than enough of the required items.
"I'm going to need a forge to get the temperature high enough. Let's see if we can find one."

Twenty minutes on the internet found a forge that could be borrowed for a fee. Dean made the early morning call and booked the oven for three hours hoping it would be enough. The only problem was it was located two hours away meaning Dean had a long drive in front of him after having no sleep. Sam wanted to go with him but Dean insisted Sam get some sleep. Dean made sure Sam was in bed then gathered everything he would need to forge the unusual blade.

Dean got the key from the owner of the forge as he was opening shop on his metal furniture store. He was handed a list of rules and instructions as well as a map to get there. Dean was able to buy some flux from the guy which meant he didn't need another trip anywhere and for an extra twenty bucks a roll of tools to rent. He got there quickly, lit the forge and pulled out his own hammers, pliers and tongs to use as well as the rented set.

There was a large anvil waiting so Dean got everything ready. Dean warmed up the blades after taking off the hilts. He had picked blades that were the same length and width to make the job easier. They were fairly thin as single blades and Dean thought they would make an impressive one-of-a-kind sword. While he waited he cut the volcanic rock to put between the blades. As he cut, he found he had a long thin narrow piece left. He could sink this into the middle of the outside of one of the blades. It may help with the kill but if nothing else it would tell the sword apart from others. There was a small crucible in the shop so he took it up and dropped a dab of borax inside to melt some silver in it. He had decided it was better to be safe than sorry and would add silver to the sword.

Dean used flux to stick the rock strips to the now inside of one of the blades then ran silver along the inside fuller of both blades. He heated the blades together in the fire until they were hot enough. Dean used the hammer and flux for the next hour to forge the blades together returning it to the heat when required. Dean had sweat through his T shirt which was all he had on his top half by the time he heated the outside center of each side of the blade and hammered the thin strips into it gently.

He used the roll of tools the owner had given him to stamp in a pentagram inside a circle on both sides of the blade at the top close to where the hilt would be and a smaller one down near the point on the central ridge. Dean ran a little of the melted silver into the lines of the pentagram. Once it had cooled, he sandpapered the symbol so it was level. Dean was happy with the look of the blade as he sharpened it with a metal file, whetstone, sandpaper and sharpening steel. After polishing the metal, he picked the sturdiest hilt with a nice pommel which he rebuilt a little to be more serviceable and stronger and rebuilt the sword in the handle. He happened to have a scabbard to put it in finishing the job nicely.

Once he had packed up and returned the key, Dean stopped at a burger place and grabbed a quick bite to eat before starting back. When he arrived Sam was still asleep so he gathered his things for a shower. As he was pulling his layers off in the bathroom he heard Sam exclaim in the other room.
"Shit Dean!"
Dean came rushing into the room to find Sam bending over the sword which he had left in the middle of his bed. Sam had the blade out of the scabbard and was turning the blade to the light coming in through the curtains.
"What Sam?"
"This is freakin' awesome. Where did you get it from?"
"I made it like I said I was going to. Where do you think I've been all this time?"

Sam looked at Dean seeing he had just his dirty, hole ridden shirt and jeans on. He smelled like smoke completing the picture.
"You really made this? Today? It looks like it should be in a shop or a museum. These little strips in the middle are great. Is this rock?"
"That volcanic stuff yeah. It's in the middle as well but I though it couldn't hurt." Dean shrugged.
"It's great Dean. The pentagrams look fantastic. It looks like a real evil repelling sword that a knight would wield. Now that I look at it I do recognize the hilt. I can't believe you made this. Where did you learn how to do this?"

Dean looked at Sam with a frown wondering if he was pulling his leg.
"Contrary to popular belief I can do some stuff."
"I never said you couldn't Dean. I just thought it would be hard to learn."
"Well it was a bit."
"When did you learn it?"
"Couple of years back I needed a blade made from an alloy that nobody had so I made it myself."
"You made an alloy?"
"Yeah. It's not that hard."
"Well I'm glad you did this, it's fantastic."

Sam ran a thumb down the blade seeing how sharp it was.
"Careful with that Sammy."
"Yeah I know it's sharp. Hey remember that special sword you stole from a Museum in New York for that creature in Oregon?'
"Yeah." Dean scratched the back of his head. "I kind of modeled it after that one cause I know you liked it."
"Liked it? I loved it and all swords ever since. Remember how I made you give it back and you bought me a small replica from the museum shop?"
"Yeah, you carried that thing around everywhere. What happened to it?"
"What always happens to our stuff. It got left behind one time. I was in a bad mood for a week after that. Anyway, look at you. Did you eat? You look skinny Dean."

With just his thin T shirt on Sam could see Dean carrying no fat at all and the work at the forge had bought out his hard muscles.
"I ate."
"You tired?"
"Not really. Just need a shower and I will be ready to go."
"Come on Dean you have to be tired."
"A little but I would rather get this job done and let you drive us home."
"Me? You sure you want me driving your baby?"
"We have a deal right Sammy? I never back out of a deal."
"Right you telling me about your hunts alone."
"The driving sport. I was talking about the driving."
"Oh yeah that too. I can go if you want to sta..."
"I'll just take a shower. Don't forget to…"
"…bundle up. I know Dean. You've said it like a million times since we've been here."

TBC

To celebrate Friday the 13th another chapter for you! Have fun.