Pirate Cutlass - Hand-Forged Curved Sabre with Bone Hilt and Knuckle Guard

Pirate Cutlass — Hand-Forged Curved Sabre with Bone Hilt and Knuckle Guard

The Everest Forge Pirate Cutlass is a hand-forged curved sabre in the swashbuckling tradition of the golden age of sail — the kind of short, fast, single-handed blade carried by sailors, privateers, and pirates from the 17th to the 19th century. Hand-forged in Kathmandu by Nepalese master smiths from 5160 high carbon spring steel (recycled truck leaf-spring stock), water-tempered, full-tang. A slender 18-inch curved clip-point blade, a sweeping steel knuckle-bow guard that protects the hand, a polished bone hilt, and a black leather scabbard — built for collectors, reenactors, cutting practice, and anyone who has ever wanted a real pirate's blade.

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 graceful curve and clip point give it genuine cutting authority, while the knuckle bow and bone grip make it a striking, hand-filling piece. Whether you are building a nautical or golden-age-of-piracy collection, dressing a costume or display, or simply want a cutlass with real handmade character, the Pirate Cutlass delivers the look and the steel.

Note: This is a historically inspired original Everest Forge design, not an exact museum reproduction of any single piece. Slight variations in weight, dimensions, bone figure, grain, or finish may occur due to the handmade nature of the item. It is live, sharpened, full-tang steel intended for collecting, display, and cutting practice — not for edge-on-edge contact sparring or LARP.

What Is a Pirate Cutlass?

The cutlass was the working sword of the sea. Short enough to swing in the cramped quarters of a ship's deck and below, robust enough to stand up to hard use, it became the signature sidearm of sailors and pirates through the age of sail. A naval cutlass typically paired a curved, single-edged blade with a guard that wrapped or swept across the hand — the better to protect it in a close, chaotic boarding fight.

This Pirate Cutlass leans into that lineage with a graceful curved clip-point blade and a single sweeping knuckle-bow guard. It is a touch more slender and elegant than the stubby galley cutlass — closer to the lighter sabres and hangers that officers and captains actually favoured — which makes it as much a display centrepiece as a functional sword. If you have searched for a pirate cutlass, a pirate sword, a curved sabre, or a naval hanger, this is the blade.

Our version honours the spirit of the original rather than copying a museum cast. The 18-inch blade is fast and lively, while remaining a fully functional 5160 spring steel sword.

Why This Pirate Cutlass Stands Apart

Product Specifications

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

Customise Your Pirate 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 fully bespoke cutlass or matched pair? Custom blade profiles, guards, hilts, and engravings are available through our Custom Forge service.

Hand-Forged Sword vs Decorative Wall-Hanger

Search for a pirate cutlass 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 look the part in a costume photo and fail at everything else.

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

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

If you like the Pirate Cutlass, here is where to look next — or commission your own.

Who This Cutlass Is For

Pirate and nautical-history enthusiasts — A curved sabre cutlass with a bone hilt and knuckle guard, the centrepiece of any golden-age-of-sail or pirate collection.

Reenactors and living-history performers — A functional, period-feel cutlass for nautical and 18th to 19th century reenactment. A blunt display edge is available at no extra charge where event rules require it.

Cutting-practice enthusiasts — Real 5160 spring steel, full-tang, water-tempered and sharpened. The curved blade is fast and built for the cut.

Costume, cosplay, and film collectors — The classic pirate-sword silhouette makes a dramatic display and costume piece, hand-forged far above mass-produced replicas.

Gift buyers — A knockout gift for the pirate fan or blade collector 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 Pirate Cutlass with 18-inch curved clip-point blade (or your chosen blade length)
• Steel knuckle-bow guard and bone hilt over a full tang (or your chosen handle material)
• Leather scabbard in your chosen colour (or a rosewood scabbard upgrade)
• 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 Pirate 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, non-standard blade lengths, 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.

Knuckle guard: wipe the steel guard down with the blade and keep it lightly oiled to prevent surface rust.

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 curve of the blade carefully. Avoid power grinders, which can ruin the temper.

Frequently Asked Questions