How to Make a Wooden Sword Handle

The Roman gladius is one of the most recognizable swords in the world and is slightly easier than other swords to replicate for historical reenactments. The gladius is symmetrical along the grind line, sharp on both sides and at the point, and has a hidden tang, screw on pommel. It is slightly easier to make a handle for a gladius than for most other swords; however, making one does require the use of a wood lathe for best results. If you have never used a wood lathe, please watch the video resources by professional wood turner Blair Davis at the end of this article before proceeding, or find a professional wood turner to assist you.

Things You'll Need

  • Wrap-around safety glasses NIOSH-approved respirator Belt sander File Power drill 1/4 inch diameter jeweler's drill bit 4 inch by 2 inch by 1/4 inch brass bar 4 inch by 2 inch by 2 inch piece of walnut wood, grain going with the length 4 inch long, 2 inch diameter white oak dowel rod, grain going with the length 2 1/2 inch by 2 1/2 inch by 2 1/2 inch cube of walnut wood Propane hand torch 1/4 inch hole brass fender washer 1/4 inch hole brass nut 60 grit sanding belt 120 grit sanding belt Sanding blocks 240 grit sandpaper 400 grit sandpaper Carnauba wax Polishing cloth
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Instructions

    • 1

      Put on wrap-around safety glasses and wear a NIOSH-approved respirator before working with nonferrous metals. Lay out and scribe the brass piece for a slot the size of your sword tang. Scribe slot lengthwise on the brass. Drill and file the slot until it fits your sword tang snugly. Repeat this step with the 4 inch by 2 inch by 2 inch piece of walnut. Make sure the walnut piece fits snugly on the sword tang, after the brass piece, with the grain of the wood going crosswise to the sword blade.

    • 2

      Scribe a slot in the 2 inch diameter oak dowel rod. Drill and file slot until it also fits snugly, after the brass and walnut pieces. Be sure to cut the slot through the length of the dowel rod, from round end to round end, and make sure the rod will fit the sword tang straight and true.

    • 3

      Drill the walnut cube across the grain, in the center, using a 1/4 inch drill bit.

    • 4

      Put all pieces onto sword tang in the correct order: brass bar, walnut bar, oak dowel, walnut cube, brass fender washer and brass nut. Tighten nut securely without splitting any of the wood pieces.

    • 5

      Turn all wood pieces on a lathe to desired handle shape or begin with a 60 grit sandpaper belt and belt sander and rough grind all pieces to desired handle shape. Rough handle shape should fit your hand when the sword handle is held with a natural grip. Finish power sanding with 120 grit sandpaper belt. Hand sand with 240 grit and 400 grit sandpaper. After sanding with 400 grit sandpaper, vigorously rub handle with double ought steel wool. Dampen all wood on handle. When it dries, vigorously rub all wood on handle with double ought steel wool a second time. Polish handle with carnauba wax and a polishing cloth.