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Ricasso on pugio?
#1
Making a first century pugio out of a single piece of steel using my angle grinder. Can't grind straight down because I don't want to damage the guard. This leaves me with the option of allowing the midrib to end in a small ricasso, with a 4" radius. Thoughts on authenticity or better, thoughts on how to solve this problem?
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#2
Whatever type of pugio you are making, it should not have a ricasso of any sort. What type of blade are you intending to make though, as there are several types of pugio blade. Simplifying things somewhat, we can talk about three types of blade, designated types 'A','B', and 'C'. Type 'A' blades feature an upstanding midrib and are often quite broad. Type 'B' blades do not feature a midrib but instead feature a pair of grooves which between them define a 'sunken midrib'. Sometimes there is another pair of grooves flanking the first two. Type 'B' blades are sometimes very narrow, although many are as wide as most type 'A' blades and most narrow to quite a long point. Type 'C' blades are less well defined than the other two types and do not feature grooves or a truly upstanding midrib, sometimes being almost lozenge shaped in section. They tend to be long and narrow.

Also, it is probably worthing letting you know that many actual blades, particularly type 'B' and 'C' blades feature narrow rod tangs, and thus do not feature a guard which would have to be avoided. The guard would be part of the grip assemblage.

If you are making your own blade, I would caution you not to model it on reconstructions but instead to look closely at pictures of originals. If you want any further advice, feel free to ask.

I hope this helps a bit.

Crispvs
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#3
This is where a file comes in handy.
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