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Replicas manufacturing technology

  This article will show the process of weapons replicas manufacturing in ElGur company


  Only the highest qualityGerman steel withthe designation 54SiCr6 accordingto ČSN 14260 norm (spring steel) is used for manufacturing blades of thereplicas (swords, fedrschwerts,rapiers,sabers, tusks...) We choose the steel ourselves. For thecrossguards and pommels, we use the ordinary structural steel.

The blade

   We always use a new material for the replicas´ blades (swords,fedrschwerts,rapiers,sabers, tusks...), because there is higher danger ofhidden inner defects in the old material.

   In some cases (swords, fedrschwerts,tusks), the blades are forged in advance in the smithy. This technique isdemanding and time consuming, but worth performi

ng because of it´s historicalauthenticity with our ancestors ways of production.

  The grooves are not milled, they are ground by hand and in some kinds ofthe blades forged in advance. The purpose of the grooves is to firm the blade,similarly as an I profile in the building industry.


Blacksmith ElGur

Blade ElGur



















   The blades arehardened industrially in the hardening specialized on 54SiCr6 material. Thus,the best results are achieved and the qualityremains under our c

ontrol. The blades are hardened to the values ​​of 50 to 52 HRc. Reaching these values, the steel combines​​ anideal ratio of hardness,elasticity and toughness, which ensures longproduct life.


   Each batchundergoes a test of hardness after the hardening. Then we subject the blades tothe test of flexibility and strength.
   We do this tests tominimize the risk of the replicas damage and to avoid any other our or yoursproblems.

Bladegrinding and polishing

   After the tests,the blade is finished by grinding to the desired shape. After that, the bladeis polished. Last polishing is performed manually. Then the blades looksauthentically as in the ancient times.


   We forge thecrossguards manually to the desired shape. The holes are not milled, we cut themthrough and then a calibration thorn is used to adjust crossguards to the exactshape of the blade tang.

   Example of making crossguards find here...


   The pommels areforged in advance manually, then we finished them by grinding. Calibrationthorn shapes the hole in the pommel exactly according to the tang shape, in thesame way as our ancestors did. We never use casts!

Two-partviking swords pommels

  The viking sword pommels consists usually of two parts, top crossguardand pommel. The first part (top crossguard) is put on the tang. Then we rivetthe tang of the viking sword. Then we put on the second part (pommel) on tworivet holding this two pars together, which are riveted.


pommels ElGurpommels viking ElGur II

pommels viking ElGur 2

pommels viking ElGur 1

pommels viking ElGur 3

Decorating techniques

- Grooving - we cut into the metal bya specially shaped smith chisels. The result is coarser grooves.

- Engraving - we use engraving chiselto engrave into the steel surface.

- Inlay - an old decorating techniqueinserting soft metal (copper, silver, gold) into the hard metal (steel). Thistechnique is very demanding on experience, precision and time. We engrave grooves into the steel.The wire from the softer metal is hammered into the grooves thus it fits therevery neatly. Softer metal then cannot drop out.

- Etching - we use this technique byusing acids and specialised alchemical tools on the steel surface.


   We prepare thehilts from the dried wood of high quality. The wood is worked into the hiltshape so it holds as well as possible and meets high standarts. Processed hiltis then wrapped by linen string, which firms and protects wooden core.
   Then the hilt iscovered by leather, wrapped by leather strap or wire etc. As you can see on thepreserved  swords, federschwerts,rapiers, sabers, tusks...in the museums and publications.


   There is a tang atthe bottom part of the blade.
   The crossguard withcut-through hole for the embedding of the blade is put on the tang. It is madealways under the pressure thus conjunction with the blade is as firm aspossible. On the end of the bottom, the pommel is put on in the same way.
   We rivet the end ofthe tang above the pommel. Both crossguard and pommel hold on the tang veryfirmly.
   We insert the woodbetween pommel and crossguard which stretch them. In this way we achieve firmreplica construction. See also „hilt".
   Thus the swordreplica is assembled.
   Production directorJan Motyčka´s note: „We don´t recommend welding crossguards and pommels tothe blade and we don´t do it. There is inner tension caused by welding in thewelded material, which can lead to the break of the blade in the place of weldor around."

Quality control

   Before the replica leaves ElGur company, weinspect individual parts carefully focusing on detail. Quality control takesplace again after the replica assembling. We evaluate the product as whole. Thereplica which doen´t meet high quality criteria can´t leave ElGur workroom.


   We preserve thereplica with oil and wrap into the foil to protect it from the corrosion. Wepack it into the box with polystyrene cut into the shape of the weapon toprevent any movement into the box while transporting.
   Now the weapon isready to dispatch to you.

Amaterial defect

   Since 2006 only 4replicas have returned back with the material defect. These weapons wererepaired in their regular warranty time.

Warranty, service, regrinding

   There is two years guarantee on ElGur´s products.

   We provide service to allour weapons following the production. From the most often demands can be mentioned stretching the new leatheron the hilt and polishing the blades.

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