Bushwhacker Cutlass - Hand-Forged Recurved Clip-Point Sword with Bone Hilt

Bushwhacker Cutlass — Hand-Forged Recurved Clip-Point Sword with Bone Hilt

The Everest Forge Bushwhacker Cutlass is a custom-designed hand-forged sword — a bold, recurved clip-point blade built to a collector's own design and brought to life by our Nepalese master smiths in Kathmandu. Conceived by Philip Lysewycz of Australia and forged to his specification, it pairs a sweeping 24-inch recurved cutlass blade with triple fullers, a polished swept steel guard, a jigged bone hilt, and a black leather scabbard finished with hand-engraved white-metal fittings. Forged from 5160 high carbon spring steel (recycled truck leaf-spring stock), water-tempered, full-tang — a genuine one-of-a-kind piece for collectors who want something no one else has.

This isn't a wall-hanger. It's a real functional sword built to the same standards as our combat-grade gladii and kukris — hand-forged 5160 spring steel, water-quenched, full-tang, sharpened to a working edge. The deep recurve and broad two-inch blade give it real presence and chopping authority, while the swept guard and jigged bone grip make it a striking display piece. The Bushwhacker Cutlass is exactly what our Custom Forge service is for — a customer's idea, sketched and specified, then hand-forged into a unique blade.

Note: This is a custom one-off design, hand-forged to a customer's specification. Each piece is made individually, so slight variations in weight, dimensions, grain, finish, bone figure, and the engraved fittings will occur — that is the nature of a hand-made blade, and part of what makes each one unique. It is live, sharpened, full-tang steel intended for collecting, display, and cutting practice — not for edge-on-edge contact sparring or LARP.

A Custom Design, Forged by Hand

The Bushwhacker Cutlass began as a design by Philip Lysewycz in Australia — a collector who wanted a bold recurved chopping sword with a distinctive swept guard and a traditional jigged bone hilt. We took that brief to the forge in Kathmandu and built it from the steel up: drawing out the recurve, grinding the triple fullers, shaping the sweeping guard, and fitting the bone scales over a full tang.

The result is a sword that exists nowhere else. The blade is a long, single-edged recurved clip-point — the belly sweeps down and then back up to a raised point, the profile of a serious cutting blade. Three parallel fullers run down the upper blade, lightening it and adding a clean, technical line. The polished steel guard sweeps up and forward in an elegant curve, and the jigged bone grip gives it a warm, antique-rifle character against the bright steel.

If you have an idea of your own — a historical reproduction, a fantasy blade, a one-off gift, or a working design — this is exactly what we do. Explore the Custom Forge service or browse our custom forged swords.

Why This Cutlass Stands Apart

Product Specifications

All dimensions and weights are approximate due to the handmade nature of the product.

Customise Your Cutlass

This is a made-to-order, hand-forged sword. Use the dropdown options at the top of this page to customise your blade before forging. All standard options are included at the listed price — no extra charge for personalisation.

Want a sword designed entirely your way? Custom blade profiles, guards, hilts, fittings, and engravings are available through our Custom Forge service — exactly how this cutlass was made.

Hand-Forged Sword vs Decorative Wall-Hanger

Search for a custom or fantasy sword online and you will find two very different types of product:

Type 1: mass-produced decorative replicas. Stamped or cast stainless steel, hollow or rat-tail tangs, no real edge, no customisation. They photograph well and fail at everything else.

Type 2 (this one): a genuine hand-forged sword in real 5160 spring steel, full-tang, water-tempered, and made to a customer's own design. Built to the same standards as our combat-grade Roman gladii and Nepalese kukris, forged by Nepalese master smiths.

The difference is fundamental: this is a real sword, not a decoration. Cared for properly, it will outlast any wall-hanger replica by decades.

Explore More from Everest Forge

The Bushwhacker Cutlass is a custom build. If you like its character, here is where to look next — or commission your own.

Who This Cutlass Is For

Collectors of unique and custom blades — A genuine one-of-a-kind, designed by a fellow collector and hand-forged in Nepal. There is no other exactly like it.

Buyers who want their own design forged — This cutlass is proof of what Custom Forge can do. Bring us a sketch or a reference and we will build your idea the same way.

Fantasy and adventure sword collectors — The bold recurve, swept guard, and bone hilt make a dramatic display piece for any fantasy or adventure-themed collection.

Cutting-practice enthusiasts — Real 5160 spring steel, full-tang, water-tempered and sharpened. The broad recurved blade is built for the chop.

Gift buyers — A knockout gift for the blade lover in your life. Add free engraving with a name, a date, or a motto for an heirloom piece. See engraving options.

How It's Made

See the full forging process →

What's Included

• Hand-forged Bushwhacker Cutlass with 24-inch recurved clip-point blade
• Swept steel guard and jigged bone hilt over a full tang
• Black leather scabbard with hand-engraved white-metal fittings
• Sharpened working edge (or blunt display edge if specified)
• Free standard engraving on request — name, date, or motto
• Care and maintenance guidance for high-carbon steel, bone, and leather
• Worldwide tracked shipping, duties and taxes prepaid (DDP)
• Satisfaction guarantee on standard configurations
• Warranty against forging and heat-treatment defects

Shipping, Returns & Warranty

Production time: each Bushwhacker Cutlass is hand-forged to order after you purchase.

Shipping: worldwide with full tracking on a DDP basis — duties and taxes are prepaid, so there is nothing further to settle on delivery. Full details on our Shipping & Returns page.

Returns: satisfaction guarantee on standard configurations in unused condition. Custom configurations — custom finish, engraving, or colours — are made to order and non-returnable. Full warranty policy.

Warranty: limited warranty against manufacturing defects in materials and workmanship.

Secure checkout: all payments are processed through encrypted, PCI-compliant gateways. Checkout security details.

Care & Maintenance

After every use: wipe the blade clean and dry, then apply a thin coat of light oil (mineral oil, camellia oil, or 3-in-1 oil).

Bone hilt: keep the bone away from prolonged damp and extreme heat, and wipe it occasionally with a little mineral oil to keep it from drying out.

Engraved fittings: polish the white-metal scabbard fittings gently with a soft cloth to keep their shine.

Storage: store in a dry environment. Avoid long-term storage inside the leather scabbard. A display stand or wall mount is recommended.

Rust spots: light surface rust is normal on 5160 carbon steel and is easily removed with very fine steel wool (grade 0000) and a few drops of oil.

Sharpening: use a quality whetstone, following the recurve carefully. Avoid power grinders, which can ruin the temper.

Frequently Asked Questions