There’s a lot of discussion boards and blog posts about using leaf spring steel to make swords. I’m going to collect some information I find about this topic here so that it’s easier to get started with and I’ll probably post some info about our project (since I’m headed to the pull apart tomorrow to see if we can get a few leaf springs to start with).
All leaf springs are made of spring steel which is commonly assumed to be AISI 5160. Removing leaf springs is straightforward but if the bolts are rusted then you want to make sure to bring some lubricant and big wrenches! I’d also inspect the springs because old springs may have fatigue cracks initiating along the edge which may be difficult to remove and finish the sword. Also, leaf springs come in various sizes so starting with an idea of the size of the sword may narrow the choice of the vehicle you are choosing to remove the springs from. I found this video about removing a Jeep Axle to be helpful with getting access to the leaf spring and beginning to remove it.
Once you have the springs in hand then you could take a look at an instructable for swordmaking or various videos of making swords like below. I’ll be posting how we do with our own efforts soon.
Dr Monroe Thoughts 