How to make a Dagorhir legal foam Roman Gladius

Dagorhir: The game known as Dagorhir is a club sport of reenacting medieval fighting, built around combat with foam weapons. Dagohir involves full contact fighting in a competitive environment, with a mixture of historical and fantasy arms and armors. Most of our equipment is homemade, and is padded to prevent major injury. Dagorhir is very different from your average LARP (Live Action Role Playing) club, as though Figure 1: Armored Roman Legionnaire (Me) many of our members do engage in some with Gladius in the Battle of the Wolves roleplaying, our members are not required (Photo Credit: Asbjorn of Dajhurgah) to speak in accents, nor have accurate costuming. The membership worldwide for the club is estimated at around 8,000. The State College practices meet on Sundays, at 1 on Old Main lawn. The club of Dagorhir, is primary focused on creating a friendly environment and exciting fantasy or medieval battlefields. The club however also maintains some historical reenacting elements.

The Roman Legion: The primary historical reenacting group is the Roman legion, of which I am a member. The Roman legion focuses on recreating the combat styles of the middle to late period Roman army, due to its interesting nature, as well as its combat effectiveness. As can be seen in figure one, the Roman legion primarily utilizes large shields, and the short sword known as a gladius for combat. Most of the legion’s shields and swords are homemade, and I myself have made around six of the short swords. The legions combat style involves forming long lines of shields, then moving into close range with the enemy, utilizing our short swords to hack and stab the enemy, pressed against our shield wall. This makes the Gladius one of the essential pieces of our kit.

History: A Gladius is a famous design of Roman shortsword, usually ranging in length from 60 to 85 centimeters (24-33 inches). The Gladius was the primary sword of the middle to late Roman Empire, due to two main factors. The first advantage was it could be held in one hand, allowing the other hand to use the shields that made the Roman legion so famous. The second advantage was the swords light weight, which allowed a soldier to move it very quickly to exploit gaps in an enemy’s defense. This made the sword effective for the Romans fighting style, as the combat of the legion involved using their large shields to enter close range then jabbing and hacking with their gladii, while their opponent’s arms were pinned by the close range. The Roman shortsword and shield allowed the Roman legion to become the global powerhouse we know today.

Required Materials: Blue Camping Mat – Should be moderately solid foam, but have around ¼ pressure compression. Ozark trail brand works well for my purposes. 1/3 Inch Fiberglass Rod – If making a sword longer than a gladius, increase thickness to ½ inch. 1/4 to 1/2 Inch Rope (Approximately 2-3 feet) – Can be of any quality. It will make up the grip section of the hilt. Approximately 4’x4’ fabric– Must be strong enough to not tear when both sides are pulled. DAP Contact Cement Carpet Tape Duct Tap

Required Tools: Saw – Can be any type of saw that will cut fiberglass rod. Sharp Knife – Must be able to cut foam. Ruler Marker Hammer/Screwdriver – to open DAP can Sewing Kit Pinking Shears or Scissors

Instructions: Part 1: Cutting the Core

Step 1: Measure on fiberglass rod around 24-33 inches, and mark that point. This will be the total length of the sword. Note that the foam should add 3-4 inches to the length, and the swords handle and pommel should take up around 8 inches from the total, so factor that into the length you want.

Step 2: Measure 2 inches on the end of the previously marked edges. These 2 inches will mark where the pommel of the sword should end. This distance is important in later steps.

Step 3: Measure 6-7 inches above the 2 inch mark for the location of the pommel. Make sure your hand fits comfortably between the pommel mark and the end of the blade mark you have just added. The distance between the marks is where the hand grip will be.

Step 4: Cut the fiberglass rod to desired length with saw. Do not cut the mark for the pommel or for the grip, just the top mark for the length of the sword. Make sure not to breathe in any fiberglass shavings given off by cutting the core.

Part 2: Making the Box

Step 1: Cut a small piece of blue foam large enough to completely cover the tip of the fiberglass rod. Secure it to the top of the rod with an X of carpet tape, making sure to attach it as tight as possible. This step is called basketing, and the piece of foam acts as a last defense against injuring another person should the core break through the rest of the foam.

Step 2: Cut two pieces of foam camping mat the same thickness as the fiberglass core. These two foam pieces will be attached on either side of the core, and will define the thickness of the sword. These two pieces must have the same thickness as the core, or the core will break free of the box, and eventually come out of the sword.

Step 3: Glue the two cut pieces of foam on either side of the fiberglass core, making sure they are completely even with each other. These two pieces will form the center of the sword, and all surrounding layers will wrap around the flat area produced by these two pieces.

Step 4: Cut a piece blue foam the same width as the flat area produced by the first two foam pieces. This piece of blue foam should be able to wrap around the sword fully, starting at the mark for the handle then bend over the tip to reach the opposite side of the handle mark.

Step 5: Glue the blue foam piece to sword, making sure that every section of the piece blue foam is attached to the lower layers. It is at the box level that most swords fail, and so this layer is the most important to be exactingly produced.

Part 3: Completing the blade

Step 1: Cut another piece of foam that wraps around the sword fully. This piece of foam should wrap from one end of the box to the other. It should also be the same width as the box.

Step 2: Glue this piece to the box. Make sure that all sides are fully attached to the lower layer and even with the blade of the sword.

Step 3: Cut a second piece of foam that wraps around the sword. Make sure it is the same width as the box, and stretches from one end of the box to the other.

Step 4: Glue this cut piece to the piece attached in Step 2. Make sure that the sides are even with the other parts of the sword and finishes where the box ends. If they are not, then the layer will slowly be torn off from blade impacts. This is the final piece on the blade. The cutting edge for the sword is now complete.

Part 4: Making the Guard

Step 1: Create a rectangle of foam that is around 4-5 inches long. This rectangle should be the width of the blade, and will make the shape for the guard. Old foam can be used for the section, and of this example I used two different pieces of foam for my rectangle.

Step 2: Glue the foam down to the side of the sword, making sure the edges line up with the blade of the sword.

Step 3: Cut a rectangle that will make up the sides of the guard. It should be even with the top of the first section for the guard, and the same width.

Step 4: Glue the rectangle to the blade of the sword, keeping it even with the section of the guard already glued on the sword.

Step 5: If using multiple pieces, attach a small amount of carpet tape along the seams between the two pieces.

Step 6: Cover guard in duct tape, making sure that every section of blue foam is covered. The less tape pieces that are used, the smoother the surface will be, and the better it will look. Duct tape is not the only material that can be used for this step, and anything that will cover the blue foam will function. The tape makes the guard appear metallic, and is also inexpensive. This makes duct tape a good option for the part, especially for a first sword.

Part 5: Building the Pommel

Step 1: Like when making the box, basket the bottom section of the dowel rod by cutting a small piece of foam able to completely cover the top of the fiberglass core. Secure it to the bottom tightly with an X of carpet tape.

Step 2: Cut a piece of foam that is approximately as wide as the blade of the sword, and around 3- 4 inches long. This piece will create the shape of the pommel. The piece should be cut to have whatever shape you want for the pommel design, the three most effective designs being a circle, octagon, or tetrahedron. Tetrahedron is the simplest design and the best for beginners.

Step 3: Using the first piece that was cut, pattern out and cut five more of the same design. Make sure they all align to make the shape or design you want.

Step 4: Select one of the five pieces that were cut in the previous step. Cut hole in center the width of the core, so that the piece of foam can slide up to the 2 inch mark.

Step 5: Glue this piece to the core, making sure to keep it even on both side. Keep the piece up against the 2 inch mark on the core.

Step 6: Attach the other pieces together by placing them in pairs, and then gluing them. At the end of the step, there should be two pairs, each two layers thick.

Step 7: Attach the pairs on either side of the central pommel section. Make sure the core is completely encased by the pommel.

Step 8: After letting the glue dry, apply several pieces of carpet tape to reinforce and attach the pommel to the core. Make sure to wrap a layer of tape over top of the tape that attaches the pommel to the core.

Step 9: Wrap pommel in duct tape to give it a metallic look, covering over all sections of blue foam. Cover up the hilt slightly, going over the carpet tape. The less tape pieces that are used, the smother surface the pommel will have, and the more natural it will look. Other materials can be used, but duct tape is one of the simpler options.

Part 6: Making the Handle

Step 1: Place DAP along the core, and wrap first layer of rope around the core, keeping the rope as tight as possible. Tightly secure the top of the rope by wrapping it with a layer of carpet tape.

Step 2: Wrap another level of rope around the core, to give an effective gripping surface. Secure the top of the rope with carpet tape.

Step 3: Wrap rope in carpet tape, coating the hilt. With pressure from use, the carpet tape will eventually conform to the surface of the sword, allowing the griping surface to emerge.

Part 7: Sewing the Sword Cover

Step 1: Place the sword on a piece fabric. Fold the fabric around sword, making sure the fabric is approximately the same size as blade of the sword.

Step 2: Cut fabric with pinking shears or scissors, so that the fabric is now a similar size to the sword. The fabric does not have to be exactly cut, as the sewing will fit the cover to the sword.

Step 3: Make sure the fabric is tight enough that it holds the form of the sword, then begin to sew. Keep the fabric tight as possible around the sword, and as sewing fold unused fabric into the interior of the cover, securing excess with a second layer of stitches. Continue until tip.

Step 4: Fold the tip of the fabric inward, and secure the fabric along the tip so that it forms with the curve of the sword. The sword cover is now complete, along with the sword.

Part 8: Become a member of Dagorhir

Step 1: Take gladius. If you have a medieval costume, then wear it. Costumes are not expected of people at their first meetings, but it adds to the fun. Don’t feel pressure, as people will just be impressed that you have your own sword.

Step 2: Find a group. The best method is to google search your area, looking for Dagorhir, or Belegarth (a similar group to Dagorhir). The sword you have made is legal for both. If you see one you like, go to practice.

Step 3: Battle.

Thanks to: http://www.dagorhir.com/ and http://www.romanempire.net/ for useful information and to Jessie Olson who first taught me how to make weapons for this club.

Bibliography: Dagorhir Battle Games. (n.d.). . Retrieved August 5, 2014, from http://www.dagorhir.com/ Images. (n.d.). . Retrieved August 5, 2014, from http://www.romanempire.net/