Hand-Forged Gladius – Carved-Hilt Sword

Hand-Forged Roman Gladius — Carved Wood Hilt with Fullered Blade & Brass-Fitted Scabbard

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Hand-Forged Roman Gladius — Carved Wood Hilt with Fullered Blade & Brass-Fitted Scabbard

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$184.99

Ex Tax: $184.99

Model: Roman Gladius Sword
Product Code: RomanGladius
Location: Kathmandu, Nepal

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Hand-Forged Roman Gladius — A Carved Wood Hilt with a Fullered Blade and Brass-Fitted Scabbard

This hand-forged Roman Gladius from Everest Forge pairs a broad, fullered blade with a carved wood hilt and a brass-fitted scabbard. It is a piece built around craftsmanship in the furniture — a turned, carved grip and pommel, a brass collar, and a leather scabbard dressed with brass throat, bands, and chape — over a genuine working gladius blade.

The blade is hand forged in Kathmandu, Nepal from 5160 high carbon spring steel, oil-tempered to working hardness, with a full tang. It carries a deep central fuller and a long point, and the carved rosewood hilt gives it a distinctive, traditional character. The standard blade is 18 inches, and other lengths can be specified before forging.

An honest note. This is a hand-forged collector and reenactment gladius — a real, full-tang spring-steel blade, not a wall-hanger and not a casting. We describe how the Roman gladius was used historically because that heritage is what the design expresses. Because every piece is forged and carved individually, small variations in the wood carving, brasswork, weight, and finish are natural marks of handwork, not flaws.

Everest Forge — Hand-Forged in Nepal

Make This Carved Gladius Yours

Choose your length, handle material, edge, and engraving — or commission a fully bespoke gladius with custom carving and fittings. Personalised engraving is included at no extra charge.

Customise This Gladius → Commission a Bespoke Gladius →

A Carved-Hilt Gladius with Brass Furniture

The gladius was the short sword of the Roman legions — a compact, balanced, double-edged blade. This version keeps that working form but dresses it with crafted furniture: a carved, turned wood grip and pommel set off by a brass collar, and a leather scabbard finished with brass at the throat, along the body, and at the chape.

The blade itself carries a deep central fuller that lightens it and gives it a clean line down to the long point. The result is a gladius that reads as a craftsman's piece — something to display and handle — while remaining a genuine hand-forged blade.

Why This Carved Gladius Stands Apart

Carved wood hilt

A turned, carved wood grip and pommel with a brass collar — the craftsmanship in the furniture is the signature of this piece.

Brass-fitted scabbard

A black leather scabbard dressed with a brass throat, brass bands, and a brass chape — a decorated carry, not a plain sheath.

Deep fullered blade

A broad gladius blade with a deep central fuller that lightens it and gives a clean, defined line to the point.

5160 spring steel, oil-tempered

The same high carbon spring steel used in vehicle leaf springs, chosen for toughness and resilience. Oil-tempered to a working hardness.

Full-tang construction

The tang runs the length of the grip for structural integrity — a real, handle-able sword, not a display casting.

Hand-forged in Nepal

Forged and carved by hand by our blacksmiths in Kathmandu. See the process on The Making and meet the team on Meet the Maker.

Specifications

Type

Carved-hilt Roman gladius — fullered blade

Blade length

18 inches (standard) — other lengths available

Handle length

6 inches

Overall length

24 inches (standard)

Blade weight

Approx. 0.8 kg

Blade

Broad double-edged, deep central fuller

Steel

5160 high carbon spring steel

Heat treatment

Oil-tempered to working hardness

Tang

Full tang

Handle

Carved rosewood with brass collar (standard)

Scabbard

Leather with brass throat, bands, and chape, included

Edge

Sharpened working edge — blunt edge available

Customise Your Carved Gladius

Most details on this gladius can be specified to your preference before forging begins. Use the options on this page to build your blade, or contact us for anything outside the standard list.

Length

Standard 18-inch blade, or specify any length from 14 to 30 inches. Forged to your dimension at no extra charge.

Handle Material

Carved rosewood as standard. Whitewood, buffalo horn, and exotic timbers are available on request to suit display or handling preference.

Edge

Sharpened working edge by default, or a blunt edge for safe display and handling — included at no extra charge.

Engraving

Names, dates, Roman mottos such as SPQR, or a crest — engraved on the blade or fittings, included at no extra charge.

Build My Carved Gladius →

Hand-Forged, Not a Wall-Hanger

An Everest Forge Carved Gladius

5160 high carbon spring steel
Oil-tempered to working hardness
Full-tang construction
Hand-forged blade with a hand-carved hilt
A decorated piece that is still a real, handle-able sword

A typical decorative replica

Stainless or unknown steel
Little or no heat treatment
Rat-tail or partial tang
Cast fittings and machine-finished handles
Built for display only — not for handling

The Complete Gladius Collection

Mainz Gladius

The early Imperial waisted pattern with a long reinforced point.

Pompeii Gladius

The standardised straight-edged pattern with a short triangular point.

Republican Gladius

The earlier, broader Republican-era form, based on the Delos find.

Ornate Roman Gladius

Engraved metalwork across the guard, pommel, and scabbard chape.

All Roman Gladius Swords

Browse the full Everest Forge gladius range by pattern, length, and use.

Who This Carved Gladius Is For

Collectors and display buyers — those who want a gladius with crafted furniture: a carved hilt and a brass-fitted scabbard, finished to display.
Roman history enthusiasts — buyers who want the classic gladius form in real, hand-forged steel with a distinctive carved handle.
Reenactors — living-history groups who want a dressed, full-tang gladius for kit and display.
Cutting-practice users — those who want a real fullered blade for controlled cutting. A blunt version is available.
Gift buyers — a handsome, lasting hand-forged gift for a history or blade enthusiast, with optional engraving.
Film, theatre, and production — a characterful full-weight blade for productions, with blunt versions for choreography.

How It Is Made

Steel selection

We start with 5160 high carbon spring steel, the same material used in heavy-duty vehicle leaf springs, chosen for toughness and shock resistance.

Forging and shaping

The bar is heated and hammered by hand into the broad gladius blade, and the deep central fuller is worked in.

Heat treatment

The blade is hardened and oil-tempered to a working hardness, balancing a durable edge against a resilient spine.

Carving and fitting

The rosewood grip and pommel are carved and fitted with a brass collar, and the leather scabbard with its brass throat, bands, and chape is finished to match.

What Is Included

One hand-forged Roman gladius in 5160 spring steel with a carved hilt
Leather scabbard with brass throat, bands, and chape
Personalised engraving where requested, at no extra charge
Care guidance for the blade, handle, leather, and brass

Shipping, Returns, and Warranty

Every gladius ships from Kathmandu, Nepal via DHL Express or FedEx International on a Delivered Duty Paid (DDP) basis — duties and taxes are handled so there is nothing to pay on arrival. Typical delivery is 8 to 15 business days from order, including forging and processing time. Some countries restrict the import of swords above certain lengths; it is the buyer's responsibility to check local law before ordering.

Standard gladii carry a 30-day satisfaction guarantee in unused condition and a 6-month warranty against manufacturing defects. Custom and personalised pieces are forged to your specification and are non-returnable. Full details are on our Shipping and Returns and Warranty and Returns Policy pages.

Caring for Your Gladius

Wipe the blade clean after handling and apply a light film of mineral or blade oil to protect the high carbon steel from moisture, paying attention to the fuller. Wipe the brass fittings with a soft, dry cloth. Store the sword in dry conditions, treat the leather occasionally with a leather conditioner, and keep the carved rosewood hilt away from prolonged damp or direct heat.

Everest Forge — Hand-Forged Roman Gladius

Order Your Carved Gladius

Choose your length, handle, edge, and engraving — or commission a fully bespoke carved gladius. Every blade is forged in 5160 spring steel and shipped worldwide with tracking, duties paid.

Customise This Gladius → Ask a Question →

Frequently Asked Questions

What makes this gladius distinctive?

It pairs a broad, deeply fullered gladius blade with a carved wood hilt — a turned, carved grip and pommel with a brass collar — and a leather scabbard dressed in brass at the throat, body, and chape. The craftsmanship in the furniture is its signature.

What is the handle made from?

The standard handle is carved rosewood with a brass collar. Whitewood, buffalo horn, and exotic timbers are available on request if you prefer a different material.

What scabbard does it come with?

It comes with a black leather scabbard finished with a brass throat, brass bands, and a brass chape — a decorated carry that matches the brass collar on the hilt.

What are the dimensions of this gladius?

The standard piece measures 24 inches overall, with an 18-inch blade and a 6-inch handle, and the blade weighs approximately 0.8 kg. The length is a choice — you can specify any blade length from 14 to 30 inches before forging.

What steel is the blade made from?

The blade is forged from 5160 high carbon spring steel, the same material used in heavy-duty vehicle leaf springs, valued for toughness, shock resistance, and edge retention. It is oil-tempered to a working hardness. Other steels such as 1095 and 1075 are available on custom request.

Is the blade sharp, or can I get it blunt?

The standard edge is a sharpened working edge. A blunt edge is available at no extra charge for safe display and handling — just note it in your order or contact us before forging.

Can I choose a different length or handle material?

Yes. The standard 18-inch blade can be made to any length from 14 to 30 inches. Carved rosewood is the standard handle; whitewood, buffalo horn, and exotic timbers are available on request. Mention your choices when ordering.

Can I have the gladius engraved?

Yes. Standard engraving — names, dates, Roman mottos such as SPQR, or a crest — is included at no extra charge on the blade or fittings. Bespoke ceremonial engraving with metal inlay is available as a premium service. See our Personalized Blades page.

Is this a real, functional sword?

Yes. It is a genuine hand-forged blade — 5160 spring steel, oil-tempered, full tang — built to be handled, not a cast display piece. A blunt version is available for those who want a purely decorative blade.

How is it shipped, and how long does delivery take?

We ship from Kathmandu via DHL Express or FedEx International on a Delivered Duty Paid basis, so duties and taxes are handled with nothing to pay on arrival. Typical delivery is 8 to 15 business days from order, including forging and processing. Custom and personalised orders may take longer.

What is your return and warranty policy?

Standard gladii carry a 30-day satisfaction guarantee in unused condition and a 6-month warranty against manufacturing defects. Custom and personalised gladii are forged to your specification and are non-returnable. Full details are on our Warranty and Returns Policy page.

Can I order a custom or fully bespoke carved gladius?

Yes. Specify any blade length from 14 to 30 inches, a custom carved handle and fittings, and personalised engraving — or commission a fully bespoke carved gladius through our Custom Forge service. We confirm every detail before forging begins.

Specification
Blade:	18 inches Long Blade made from carbon steel 5160
Total Length:	25 inches Long in total
Handle:	7 inches Long Full tang Handle made from Rosewood
Weight:	770 Grams Approx
Note:	Please note: As each sword is individually hand-forged, slight variations in measurements, weight, and appearance are natural and add to the uniqueness of each piece.