Spartacus: War of the Damned Gannicus Aluminum Prop Sword

As a huge fan of the TV series "Spartacus," I am determined to build cosplays for all my favorite characters. So naturally I have a lot of prop swords the build.

Aluminum Flat Bar (2"X1/8"X36")

Poplar Board (3"X1/5"X36)

Copper Spray Paint

Flat Black Spray Paint

Wood Glue

Matte Clear Coat

Find high quality photos of your desired prop for reference.

Draw the design onto the flat-bar and cut it out with a grinder or whatever you have available to cut metal. Trace the basic handle shape onto the poplar and cut it out. Then, grind the bevel for the blade on the edges on both sides. Then, attach the wood pieces by screwing them together with the aluminum sandwiched between the wood. Sand the wood down to the aluminum and contour and smooth the edges to desired form.

Using a file, cut a line to separate what represents the bone part of the hilt from what is to look like the metal cross-guard and pommel.

Mask the "bone" part of the hilt and the first 8 inches of the blade and paint the cross-guard and pommel with the copper color. Spray another coat and allow to dry. Remove the tape and dust the wood with flat black. Sand the whole hilt to add weathering and reduce sheen. Dust the blade with flat black. When dry, sand the blade lightly using a cross-hatch pattern. Sand the edges of the blade a little harder to bring out the bevel (make it pop). Spray a matte clear coat on it and you're done!