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Originally Posted by fspic
This blade may have been a lost cause before any work was done on it. The only thing that can be done is a chemical cleaning, filing smooth and then finding a way to fill in the pits with metal. I found a shop about five years ago which is willing to try spray welding of on this type of problem. This would be tried in very local areas first. A form of gas welding might work using certain alloys. However it would merely permit re-shaping the blade which would be a reconstruction more than a restoration. It would likely show the alloyed and filed areas as a separate color.
Coin silver has a relatively low melting point. Zinc is even lower. If you are really desperate and have the resources it might be possible to use these metals in sequence. Even an electroplate could be used to fill the final top layer of a filled blade. After finishing the blade would merely look "old and not maintained" instead of like a total disaster. The object is to merely restore the shape and appearance to make a more presentable wall display.
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Salaams fspic, Ypoznan, Evgeny_K et al~ The electroplating is maybe not a bad idea. What caused the damage? The Dremel or the desalting ?... It looks like it was sandblasted?? I must look up dremel ah ! Its the dreaded power tool in restoration...
I think that may have done the damage. By the way has anyone ever done electrolysis on severely rusted blades?
www.instructables.com has a couple of tips for this technique though I have to say with a blade as badly corroded as this was...it was never going to be easy. I would go for a few days in something mild like coke or lemon salt clean it off with soapy water and after drying get it covered in restoration wax.
Regards Ibrahiim al Balooshi