Lifesize Gladius – Roman sword (sturdy)

This is a lifesize version of a Gladius, the legendary  sword of the roman empire. 

Its length is 70cm but its separated in different parts to be also printable on the A1 mini. To get it sturdier, its built around a 11/32inch wooden arrow shaft and connected by pins and glue. Very easy and convenient to assemble.

This model is great as a display showpiece especially with a nice paint job or silber silk PLA as I used it. But its also great to swing it around to get a feel of the size of this type of sword and feel a little bit like a roman warrior ;)

 

For all of you who dont have or want to buy a wooden arrow shaft, I added some printable rods you can use instead. But its not as sturdy and harder to assemble compared to the arrow shaft.

 

Parts needed:

• 59cm 11/32inch wooden arrow shaft 
  or 
  printed rod parts in the print profile
• Glue (and activator)

Tools needed:

• fine sandpaper
• workshop paper towel to remove liquid glue

Print tips:

For printing the blade part and the pins bed adhesion is key. I recommend the textured PEI plate or similar plates and maybe to clean it before or use some glue. I printed one blade part after another to decrease the chance of one loose piece ruining all. 

I will provide a print profile with brim in the next days. The problem with brim is, that the transition between the blade parts is more visible.

I flattened one side of the pins and rods to increase their adhesion area, since then I had no more problems printing them.

You dont need any supports for the prints.

 

You just need to print the rods if you don't have a wooden arrow shaft.

 

Assembly:

1. Cut your arrow shaft to 59cm
2. Do a test assembly without glue
   1. stick all the parts on the shaft as shown in the pictures
   2. use the small pins to connect the blade parts
3. Check if the tolerances of the pins fit. I had varying tight fits depending on the used material.
4. Check if the blades fit nicely to each other without a visible gap
   1. use some sandpaper on a flat surface to reduce the gap
5. Disassemble it 
6. Start the assembly with glue
   1. start a the handle part and finish with the blade parts
   2. be careful to not use to much glue
7. Have fun with the sword!

Two of the small pins are spare pins ;)

 

Historical reference:

This Gladius is not 100% historical accurate, because they had no 3d printers and I am not a roman blacksmith :D The design, the size and the proportions of the gladius are based on historical findings of the Pompeji type gladius and various replicas.

 

Feedback:

I hope you will enjoy my design and have fun feeling a little bit like a roman fighter.

I am happy to receive feedback, also about new projects. I am thinking about doing a version with a different blade type and some decorative elements on the handle. Or maybe a sheath for it. Or maybe a long sword from the middle age to compare them….

 

I am looking forward to see you makes and your color choices and maybe also some painted one!

Boost MeA boost would be great :)