01-29-2008, 05:24 PM
Since about a year ago I started collecting pictures and information about pugios, because I wanted to start a new project. Gradually I decided to reconstruct a Type A and the since I had the most info on the Sisak pugios (The Militaria Sisciensia book is great), the choice was simple it had to be Sisak no. 60 (according to the MS book).
In October 2007, work finally started.
The original:
http://www.fileden.com/files/2007/2/21/ ... u02lp5.jpg
http://www.fileden.com/files/2007/2/21/ ... IM2372.JPG
1) The Blade:
It is a blade with a simple midrib, it is possible to see on the backside of the original and I also saw x-ray pictures of it.
I made the blade with the stock removal method. I should have hammered it, but and believe me I tried, it didn't work for me. Couldn't generate enough heat. I didn't want to use acetylene gas like I did for my helmet, because it is quite expensive.
Anyway, stock removal is easy enough to do and the result is very satisfying.
I started with a piece of hot rolled steel about 30 cm long by 5 cm wide and very important, not to thick: 3 mm.
http://www.fileden.com/files/2007/2/21/ ... IM2348.JPG
First I made a reconstruction drawing on millimeter paper, like I did for all the parts (The next best thing to a CAD, since I 'm not that familiar with computers).
Then I copied the drawing on to the workpiece and sawed, grounded and filed it in to the right shape.
http://www.fileden.com/files/2007/2/21/ ... IM2347.JPG
Next step is to divide the workpiece in to four sectors and work on each sector separately. I grounded and filed it down to the right slope starting from the center. I made markings on the side of the workpiece to make sure I didn't grind it lower than the middle and ruin the blade.
I used these to do it:
http://www.fileden.com/files/2007/2/21/ ... IM2351.JPG
Here you can see some stages:
http://www.fileden.com/files/2007/2/21/ ... IM2349.JPG
http://www.fileden.com/files/2007/2/21/ ... IM2352.JPG
http://www.fileden.com/files/2007/2/21/ ... IM2354.JPG
http://www.fileden.com/files/2007/2/21/ ... IM2350.JPG
http://www.fileden.com/files/2007/2/21/ ... IM2353.JPG
You can make the midrib by clamping a straight piece of metal on to the workpiece (a little off center according to the width you want the midrib to be) and go a long the blade in progress with your file in long passes, be sure that the edge of your file touches the piece of metal all the way. Wear thick gloves, because when you come near the point of the blade with your fingers, it can become bloody!
This is about 8 hours of work for me.
I am going to leave it for now, you get the follow up tomorrow or in the next few days.
In October 2007, work finally started.
The original:
http://www.fileden.com/files/2007/2/21/ ... u02lp5.jpg
http://www.fileden.com/files/2007/2/21/ ... IM2372.JPG
1) The Blade:
It is a blade with a simple midrib, it is possible to see on the backside of the original and I also saw x-ray pictures of it.
I made the blade with the stock removal method. I should have hammered it, but and believe me I tried, it didn't work for me. Couldn't generate enough heat. I didn't want to use acetylene gas like I did for my helmet, because it is quite expensive.
Anyway, stock removal is easy enough to do and the result is very satisfying.
I started with a piece of hot rolled steel about 30 cm long by 5 cm wide and very important, not to thick: 3 mm.
http://www.fileden.com/files/2007/2/21/ ... IM2348.JPG
First I made a reconstruction drawing on millimeter paper, like I did for all the parts (The next best thing to a CAD, since I 'm not that familiar with computers).
Then I copied the drawing on to the workpiece and sawed, grounded and filed it in to the right shape.
http://www.fileden.com/files/2007/2/21/ ... IM2347.JPG
Next step is to divide the workpiece in to four sectors and work on each sector separately. I grounded and filed it down to the right slope starting from the center. I made markings on the side of the workpiece to make sure I didn't grind it lower than the middle and ruin the blade.
I used these to do it:
http://www.fileden.com/files/2007/2/21/ ... IM2351.JPG
Here you can see some stages:
http://www.fileden.com/files/2007/2/21/ ... IM2349.JPG
http://www.fileden.com/files/2007/2/21/ ... IM2352.JPG
http://www.fileden.com/files/2007/2/21/ ... IM2354.JPG
http://www.fileden.com/files/2007/2/21/ ... IM2350.JPG
http://www.fileden.com/files/2007/2/21/ ... IM2353.JPG
You can make the midrib by clamping a straight piece of metal on to the workpiece (a little off center according to the width you want the midrib to be) and go a long the blade in progress with your file in long passes, be sure that the edge of your file touches the piece of metal all the way. Wear thick gloves, because when you come near the point of the blade with your fingers, it can become bloody!
This is about 8 hours of work for me.
I am going to leave it for now, you get the follow up tomorrow or in the next few days.
Quintilianus/Jurgen Schultz
Member of Legio XI Claudia Pia Fidelis
AUDI ET ALTERAM PASTEM
Member of Legio XI Claudia Pia Fidelis
AUDI ET ALTERAM PASTEM