Reconstruction Sisak pugio

[Quintilianus]

OK, second try.

2) The handle:

The handle consists out of two iron parts with two bone inserts.
To make the iron parts I used again 3 mm thick hot rolled steel.
I transferred the pattern of the building plan on to the metal and cut the shape out, two times.
After studying the photos of the original it became clear that the handle is thinner at the ends then in the middle, I have seen this with other originals as well. You can see this on the drawing in the first picture. So I grounded and filed the guard and pommel of the two workpieces until it looked good and went on.
Next step is filing the pieces into the roof like shape. I first scratched the necessary lines on to the metal.
It is not easy to keep the center line, If you file it past it, the piece is ruined. This also counts for the rim of the workpiece which has no thickness at all and it is easy file to much off.

http://www.fileden.com/files/2007/2/21/ ... IM2373.JPG

http://www.fileden.com/files/2007/2/21/ ... IM2371.JPG

http://www.fileden.com/files/2007/2/21/ ... IM2376.JPG