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Mainz Gladius
Late Roman Republican period to very early Imperial period style sword

Roman Recreation Roman Reconstruction how to make a sword how to make a Mainz Gladius custom or customize

My Mainz Gladius from Deepeeka... the blade and hilt are well done however; I was rather disappointed with the embossing workmanship... it seems a bit 'rushed'. The scabbard does not look anywhere near as good 'in hand' as it does in the photographs below.  Anyways, I also wanted my Mainz Gladius to have a two tone silver & gold with white look so that it would better match my armor.

 Original              Modified scabbard       Modified handle
Roman Recreation Roman Reconstruction how to make a sword how to make a Mainz Gladius custom or customize

Roman Recreation Roman Reconstruction how to make a sword how to make a Mainz Gladius custom or customize
First I pulled off the brass tacks from the clamps
Once all four were removed the edging just pops away from the scabbard


I then cut and embossed the silver embossing sheet foil (which I honestly have to say is actually pewter not silver)
Lastly you can see the original scabbard plates (brass Mainz Gladius from Deepeeka) next to mine (silver)

  

I honestly wanted to use 'cold enamel' to add the red highlights and white trim however, both art supply stores were out of stock, and the only place online I could find was on back order for a month so, I used the next best thing... enamel paint. Please don't call the authenticity police on me... I could always enamel them in the future!
Roman Recreation Roman Reconstruction how to make a sword how to make a Mainz Gladius custom or customize


Roman Recreation Roman Reconstruction how to make a sword how to make a Mainz Gladius custom or customize

Next I cut the top off a hardwood cane I picked up on EBay for $26.00. I had to use my Dremel to cut out the Pummel to get to the hex nut and removed it (how they got it in there I have no idea!)
Roman Recreation Roman Reconstruction how to make a sword how to make a Mainz Gladius custom or customize


Roman Recreation Roman Reconstruction how to make a sword how to make a Mainz Gladius custom or customize

The Pummel of the Deepeeka Mainz Gladius just screws off but the bone handle had to be sawed off. There was a hard putty like substance within the round bone handle to keep it from turning.
Roman Recreation Roman Reconstruction how to make a sword how to make a Mainz Gladius custom or customize

      
Roman Recreation Roman Reconstruction how to make a sword how to make a Mainz Gladius custom or customize

Initially the eagle head didn't quite line up with the hilt so I had to take a sander and file to it to make it match up.


Roman Recreation Roman Reconstruction how to make a sword how to make a Mainz Gladius custom or customize

Then I drilled a hole in the eagle head with a drill press, placed some JB Wield in the hole, added some Elmer's Glue to the bottom of the eagle head handle and the top of the hilt. I was sure to cut some grooves in into the hilt and then some additional grooves into the handle in the opposite direction before gluing, for a really strong bond. Then I let dry over night and... that's it!

A Mainz Gladius with an Eagle's head handle
Roman Recreation Roman Reconstruction how to make a sword how to make a Mainz Gladius custom or customize


Roman Recreation Roman Reconstruction how to make a sword how to make a Mainz Gladius custom or customize
Roman Recreation Roman Reconstruction how to make a sword how to make a Mainz Gladius custom or customize
Roman Recreation Roman Reconstruction how to make a sword how to make a Mainz Gladius custom or customize
Roman Recreation Roman Reconstruction how to make a sword how to make a Mainz Gladius custom or customize