RomanArmyTalk

I have started a project which I may come to regret...a pugio using the "stock reduction" method (grinders, belt sanders files etc.). I started off with a piece of flat m/s stock 80mm wide and approximately 8mm thick (a little bit thicker than I wanted but I figured I could deal with that). The blade and scabbard I am attempting to "re-create" is the Leeuwen as seen below:

After many hours and hack saw blades I ended up with fore arms like Popeye and this...



Rough shape and still plenty of work to do. In order to make the fuller I clamped a straight piece of steel as a guide a few mm either side of the blade centre line and run an angle grinder down to a depth of about 3 to 4 mm, and repeated on the other side of the blade.

An hour or so with the angle grinder and I got this....



Still lots of work to do, but not a bad start. Not happy with the shape yet - it does not have that shapely female curviness to it that the actual blade has but it is early days.

Over the next few weeks I will post progress pics for all to see and chip in with advice etc. and let you know if the neighbours are still talking to me hock:

Nicely Done!! I looked under the bed today, trying to find time to get into the workshop.....alas...still looking!! Laudes

Thanks Wes - I know what you mean about time. Work just keeps getting in the way damn it!

Very nice!
I'm very interested in your progress. I began a very similar project but stopped it. Your project and results encourage me to take it again.

My little problem is the lack of tools at this moment. Do you think with only an angle grinder (and hand tools like files) it would be enough?

Laus and good luck!

Regards

At this stage it seems to be - other people also use belt sanders I understand. With some practice you can actually be quite accurate with an angle grinder, and files for access to the more delicate/difficult areas.

The fuller I shall tackle with a dremel - fantastic tool!

Look forward to seeing your project back on track!

Thanks!
I think in this project I`ll make no fullers. I know dremmel is a superb tool, I must get one for Christmas!
Now, I will figth wtih the angle grinder in order to made a proper shape...

Regards and looking for you progress.

Well done Bary! Good trick using the clamped metal as a guide for the grooves.

Excellent work Svlla, I will post a pic or two of other bits of gear that may help to finish the Pugio of.
Regards Brennivs

For closer work, you might experiment with clamping the grinder to the table top, and holding the blade against it with your hands. Obviously be careful.

The idea being, if the grinder is running, but stationary, it's easier to make fine motions with the lighter piece.

Thanks for the tips guys - I look forward to seeing the other bits of gear that may help Brennivs

Demetrius - thanks for the good suggestion. I may try this on another piece.

Nice work so far Barry. I look for to watching it progress.

Be careful about talking about 'fullers'. As far as I am concerned they did not exist on pugiones in their normal sense (ie a groove down the centre of a blade to lighten its weight). Type 'B' blades do feature grooves (sometimes two and sometimes four) but these should probably not be confused with fullers. Unlike type 'A' blades, type 'B' blades do not feature an upstanding midrib. The midrib on a type 'B' blade therefore is created as a 'sunken' midrib formed by the grooves either side. These grooves are very rarely the pair of dead straight grooves you often see on bad reconstructions such as the atrocious Hanwei pugio by Paul Chen and tend to have a slight shape to them. They often come together an inch or two from the point of the blade to finish off the midrib. Sometimes there is a second, outer, pair of groove which tend to 'emphaise the shape' of the inner grooves. Sometime though, they simply run down as another pair of grooves. I can probably send you some pictures if you want.

Crispvs

I take it you mean like the pugio developed by peronis and Deepeeka Crispus?

Crispus,

I was hoping you would see this thread - any help thankfully received!

Latest progress update below:



The central raised rib will be reduced in size to get as close as I can to the look of the original piece (at least from the photos I have). I then intend to mark out the "groove" around the raised rib with a cold chisel (very carefully!).