Hi everyone,
I have a 1840 NCO Sword by Windlass Steelcraft, and it has, as seems typical of this model, become very loose in the hilt. I have heard of many people taking the sword apart and reassembling it to be more sturdy. I am new to this and was wondering if anyone could explain in some detail (preferably with pictures) how this is done and recommend a way of reassembling it. I was thinking using Epoxy for the reassembly and would greatly appreciate any feedback as to why this is a good or bad idea.

Thanks!

Well, this is a common problem on Windlass swords, and if I remember correctly, the 1840 NCO has a peened pommel (I don't know if that's a problem for you). Is the blade making a clanking noise or is it fully moving around? If it's only clanking a bit, I recommend putting some spacers in between the gaps where the blade meets the hilt. Spacers could be pieces of brass, or any sort of metal piece you think might work. This worked for my Windlass, and it hasn't made any noise to date. I would however use a little epoxy to keep it tight as a precaution, just so you won't have this problem again. I'm afraid I don't have any pictures of the process, but perhaps another forum member could be of more assistance.

All the best,
Nathan Wuorio.

Thanks for the advice, but the blade is rotating slightly. What do I do in this case?

I would buy 1840 NCO sword. Because there is a chance for you getting one with a turning blade.

This Workshop article should help:
http://www.myArmoury.com/feature_bench_ws_cfo.html

Take a look at the article, How to Fix a Loose Hilt over at Bjorn Hellqvist's website. It describes a technique for repeening the pommel, usually for medieval swords, but it might apply to yours. - http://bjorn.foxtail.nu/swords.htm . It won't help you fix a rotating blade.