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D Garrett





Joined: 13 Jul 2011
Reading list: 1 book

Posts: 11

PostPosted: Sat 17 Sep, 2011 10:01 pm    Post subject: Customized Windlass Mainz Pattern Gladius         Reply with quote

I recently purchased a used Windlass Mainz Pattern Gladius and decided to make a few modifications to it in order to improve its' appearance and handling.

First I disassembled the sword.

I then radiused the tang / blade shoulder junction. While I had the sword apart I re-polished the blade from an almost mirror polish to a satin polish using a gray Scotch Bright pad.

Next I stripped the the old finish ( a reddish stain that hid the grain of the wood) off the guard and pommel. I re-finished both of these pieces using Watco Danish oil.

The plastic grip was replaced with a hardwood (I can't remember which hardwood) grip I made.The replacement grip starts out round in cross section near the pommel and gradually changes to a more oval shape as it gets closer to the guard. It also was given a Danish oil finish.

At this point I replaced the 1/4" steel guard plate with a 1/16" brass plate and inset it into the base of the guard.

I also filed grooves into the pommel nut to improve the way it looked.

Lastly I reassembled the hilt using epoxy to help strengthen the hilt.

Here are some photographs of the sword:

The sword in its' original configuration.


The modified sword.





The blade tip showing the satin finish.


The Hilt




The guard plate


The pommel nut


It was a fun project to do. So much fun in fact, I just bought an used Windlass Pompeii Gladius and plan on modifying it.
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Lewis Ballard




Location: Houston, TX
Joined: 27 Dec 2009

Posts: 66

PostPosted: Tue 20 Sep, 2011 8:23 pm    Post subject:         Reply with quote

I think that's a vast improvement, and the fact that you did it yourself simply makes it better. Kudos, props, praise!
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D Garrett





Joined: 13 Jul 2011
Reading list: 1 book

Posts: 11

PostPosted: Tue 20 Sep, 2011 11:20 pm    Post subject:         Reply with quote

Thank you Lewis. My Windlass Pompeii Gladius should be even better if everything goes as planned.
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