This is a video from Man At Arms detailing the process of forging a traditional Japanese katana (in this case a Hattori Hanzō replica from Kill Bill). They even start by making their own steel from iron ore. The whole process was pretty fascinating, and the finished product (which has over 3-million layers) puts the cheap katana replica I bought from the weapon kiosk at the mall look like a turd. A turd I could still polish and stab my roommate with, just so we're clear.
Keep going for the whole 20-minute video while daydreaming about being a ninja.
Thanks to Blasfrenzy, who tried to tell me the pen is mightier than the sword which is why I have a pen in my neck right now.