He continued working on the metal he had... making it out into a long strip and beginning the folding process. After a while of heating, folding, pounding, cooling, reheating, and continuing the process over and over, he started to have something that was resembling a sword's blade, although it was not sharp. Using that "blade" as a mold, he began to form himself a sheath, giving himself a little bit of room-allowance so that he can make a mechanism to lock in the blade.