I have an albion augustus and worry about the wood hilt being prone to damage. How would you address damage and repairs?

I would send it back to albion if it were damaged badly, or use maybe wood putty, if it works.

Are there any good smiths who do custom rehilts out there?

I don't know if it may help but Albion has a few extra Roman hilt parts (guards and pommels) on their Moat Sale page...

http://www.albion-swords.com/moat.htm

I'd sand off the worst of the ragged bits and wear it with pride. The best way to keep something pristine is to leave it on the wall. If you're going to use it, it's going to look used at some point. Nothing wrong with that.

Matthew

I agree with Matthew....I once built a gladius for a friend. He loved the blade, but said the wooden hilt looked 'too good'. I disassembled it , and beat the hell out of the wooden parts on my gravel driveway paving. Then, I restored the wood, leaving the ding marks. He fell in love with it instantly. Wear those dings with pride!.....McM

I guess I am just not in love with the wooden hilts. I think it would look really nice with a fabricated pugio hilt....not sure if it would fit or not. Any armourers specialize in hilt fabrication out there?

Well, a pugio-style hilt would not be appropriate for a sword, unfortunately. But bone was common! There were several ways to make bone pommels and guards, which would be more ding-resistant than wood.

Matthew

Why would it not be appropriate?

Just because there is no suggestion that gladii ever had pugio-style hilts. No archeological remains, and no artwork that shows such a thing.

Matthew