How to Make a Wooden Gladius

The gladius was the sword used by the Roman infantry or foot soldiers, who had to fight while holding large and bulky shields with their left hand. These swords were 3 feet long, and equally heavy and sharp with their double edges. These swords can be made into replicas of smaller sizes, with blunt tips and edges, so that they can be used as accessories for a school play, backyard game, or for a costume party for kids.

Steps on How to Make a Wooden Roman Gladius

Step 1 - Making the Blade
In order to make the replica of this ancient Roman weapon, you will need to mark two 21 inches long straight lines on a smooth plywood, while keeping them 2 inches apart. Now demarcate the triangular tip of the sword, by making two equal markings, so that the sword's tip is not too prominent. This will keep children safe from injury. Now cut the piece along the demarcated measurement, so that you have the main body of the blade. Use a strong sandpaper to smoothen all the sides of the blade, and especially the surface.

Step 2 - Hexagonal Base of Blade
This hexagonal piece will make the base of the blade and the attaching piece to the handle of the sword. You can make this base in an arc as well, however, the arc or the hemisphere is more difficult to cut out when dealing with wood. Mark the measurements so that the base piece is 2½ inches broad, thereby being a bit broader than the blade. Let this piece be 3 inches tall. Now cut the wood in such as way that the area where the handle is to be fixed is broad enough, but less broader than the blade of the sword. Cut the sides of the base in order to create the hexagonal shape. Now stick this base to the end of the blade, using wood adhesive glue. Make sure the base is exactly in the center of the blade. Smoothen this piece as well after it has been firmly stuck in place.

Step 3 - Making the Pommel or Handle
Let the handle be 6 - 8 inches long. Let it be 1½ inches broad. Cut into shape, in order to make a perfect rectangular piece of thick plywood. Now soften the edges, so that it becomes comfortable to hold. Stick this handle to the open tip of the hexagonal base.

Step 4 - The Base of the Sword
The base of the sword will be as long as the base of the blade we made earlier. So let this piece of wood be 2½ inches broad and 3 inches tall. It can be perfectly rectangular, after which you will need to smoothen the edges. Or you could cut the edges off slightly and thereafter smoothen the out. Stick this piece to the central tip of the handle. Your Roman wooden gladius is game!

Remember to rub the entire sword with sandpaper so that it is completely smooth. Apply wood varnish to make the sword a tad shiny and new looking. Make sure the tip of the sword is as blunt as possible, if not, keep smoothening it until it becomes more blunt.

Replicas of ancient Roman weapons, such as the wooden gladius, on sale, will cost you about US $25.00, whereas the only expense you will be incurring when you make it yourself is the plywood. That too if you choose to purchase it or instead you can use scrap wood too, from a broken chair or other furniture. There are other ways of making a wooden gladius, however, the above mentioned method is more suitable for beginners, who are just learning carpentry.