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Old 26th March 2010, 11:00 AM   #8
katana
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Join Date: Jan 2006
Location: Kent
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Hi Lew,
personally I would go with steel/iron , to get a more authentic look, the sheet metal should be 'hammered' ....as modern sheet would be too uniform. Unfortunately hammering 'cold' sheet will 'work harden' the metal, making it more brittle....so before trying to form the sheet into a cone (to fit the spike)....the hammered piece needs to be annealed....ie heating to a 'dull red' colour and then left to cool slowly, this makes the steel more ductile whilst retaining its strength.
Copper sheet will also work harden if hammered and would need similar treatment.

All the best

David
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