Windlass' New Coustille -- myArmoury.com

Josh Wilson · Posted: Fri 19 Jul, 2013 5:42 pm Post subject: Windlass' New Coustille

I wanted one of these for a rebuild, and found this one on Ebay for an epic price. Here's a stock photo and stats from Kult of Athena.

Overall Length:22''
Blade:16 3/4''
Weight: 1 lb 9.2 oz
P.O.B.: 15/16''
Thickness: 4.4 mm - 2.7 mm
Width: 50.8 mm
Grip Length: 4 7/8''

Over all I like the length and balance but I did not like the shape of the handle. It felt too bulbous, and like I didn't have a good grip on the bottom half of it, because it was too wide at the top. After a little bit of time on the belt sander, I think I have it how I want it, and have glued on some risers. I have also stripped the finish from the scabbard and rubbed in some glue mixture to harden the leather.

Here's a picture of the tang with a ruler, in case anyone was curious.

I'll have more pictures to come.

Ian Hutchison · Posted: Fri 19 Jul, 2013 9:42 pm Post subject:

I agree, the handle does look bulbous, I'm also not a fan of handles that taper so much at the extremes. I like the design for your new handle, should come out looking good.

S. Sebok · Posted: Sat 20 Jul, 2013 3:59 am Post subject:

I own the same sword, I been debating on modifying it I just dont know anyone who could possibly help me as I have zero leatherworking skills myself. Cant wait to see more of your steps on how you're modifying this.

Josh Wilson · Posted: Fri 26 Jul, 2013 1:30 pm Post subject:

On the last re-gripping that I did, I used cotton cord to wrap the handle to make the risers. However, I couldn't find what I did with that roll of cord, so I decided to use the yarn pictured above since it was the diameter I was going for. It did not want to hold up to having a piece of wet leather up against it, and I ended up taking that off and using some leather lace.

Got it wrapped, and dried...

To do the sheath I wrapped the scabbard core in masking tape, marked a line down the back center and cut it with a razor. Then I stick the tape to some brown paper and cut out around it. This I lay down on the leather and trace around. Then I add some seam allowance all around it by setting my compass and dragging it around the perimeter of the shape I just drew. After I cut it out, I use a fork to punch holes on the inside line I made by tracing my template. I like using a fork because of how far apart the tines are. Then I sew it up around the core, adding glue as I sewed up.

Before putting it back together, I drilled the pommel, and peened a rivet in the top for cosmetic appearances. Unfortunately I didn't think to get pictures of that...

I dyed the handle green, and the sheath dark brown. This is how it turned out...

David Clark · Posted: Fri 26 Jul, 2013 2:17 pm Post subject:

Wow, that looks very nice!

J. Hargis · Posted: Fri 26 Jul, 2013 5:15 pm Post subject:

Mercy me, what a difference! Good show, Josh.

Jon

Jean Thibodeau · Posted: Sun 28 Jul, 2013 8:21 am Post subject:

Bryan Heff · Posted: Sun 28 Jul, 2013 11:52 am Post subject:

Looks great. Your riser pattern and grip turned out super nice. I major improvement to the original sword!

Ian S LaSpina · Posted: Sun 28 Jul, 2013 12:45 pm Post subject:

Very nice job! What weight leather do you use to re-wrap the grip? I'm interested in trying my hand at a re-wrap.

Scott Hrouda · Posted: Sun 28 Jul, 2013 9:22 pm Post subject:

Thank you for sharing! I love DIY projects where someone's not afraid to rip something apart and make it their own. You did an excellent job taking a ho-hum weapon and really jazzing it up!

Josh Wilson · Posted: Mon 29 Jul, 2013 11:04 am Post subject:

Thanks for the compliments fellas! I used 2-3 oz leather for the grip and scabbard.

Patrick Kelly · Posted: Mon 29 Jul, 2013 3:44 pm Post subject:

Well now, that has an entirely different look to it. Well done!