Making the Zombie Tools Legionnaire - A Roman Gladius - Spanish Celt Inspired Design - Short Sword

How is it made? Well, here you go...an inside look at the craftsmanship at the Zombie Tools Pirate Shop.
Enjoy!
Get your Zombie Tools here: zombietools.net
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[@jorgefernandez6407]

The Mainz Gladius is my most favorite sword... Or so I thought until I saw this one. The Legionnaire has become a "grail" blade to me. I'm going to have one especially, after watching this video! No bullshit...

[@zombietools]

High praise. Thanks Jorge!

[@arkoutarkout3654]

The genius in that grinding girdle should not be over looked @@zombietools

[@KurNorock]

Was not expecting the grind to be done by hand with an angle grinder. I thought you would have had a jig on a belt grinder. Much respect to that man's steady hands.

[@bartweijs]

Actually, half the knife and sword makers around the world hog off the majority of the material on a angle grinder; and finish on a belt grinder. It depends, are your belts cheaper then your fiber discs ? in this corner of the world, fiber discs are significatly cheaper than belts; so you tend to use belts for the final shaping; belts are more accurate. If belts would be cheaper; I'd use just belts. However, I've seen knifemakers produce excellent non-fullered daggers with just angle grinders. The thing I'm worried about is some of the ferric chloride getting between the steel and the aluminium handle ... How do you mitigate that problem ?

[@nodjr1595]

@@bartweijs I think with how they pour the acid on rather than dip or soak, as well as with how tight the scales are held on, the amount of acid that can seep into the cracks is negligible and ofset by the fact that most people also neutralize the acid along with washing it off. Even if some acid remained inside the crack the amount wouldnt cause any amount of damage to the blade, and since the acid is pre corroding the metal it would also give it some protection from moisture that seeps in.

[@thumperthumper5322]

Amen Amen it's a amazing job

[@joshm3484]

I wasn't expecting it to be done after tempering

[@zadeify9596]

Sharpening with free hand is hard af but when you know how, you know how.

[@AniwayasSong]

You've got me. I'm not made of $$$, so it takes me time to save-up for self defense tools I admire. Thank you for making and sharing these videos, so folks like myself can see what you're doing!

[@jamesdeek7039]

Been buying from you guys since the start and i must say you have perfected your craft. Your stuff is worth every penny and the fans are awesome folk too

[@zombietools]

Thank you. Cheers!

[@gloving4hire]

Do you find Xiphos has enough guard/hand protection? I want one so bad but dont want to order one because none of the reviews are very detailed in the handling of it

[@dreadthemadsmith]

I've always loved the utilitarian look and style of these weapons, nice to see that it extends to the making of them.

[@zombietools]

Many thanks.

[@AniwayasSong]

Yes! I'm no fan of 'Fancy.' I want/demand 'FUNCTION!' Give me a tool that I can properly maintain, and then expect will properly do the job intended? I'm sold!

[@seabournewolf2298]

I’d love that with simple hickory scales (wrapped in leather)

[@shaggrat]

Serious respect. I will be buying one of your tools soon. The economy slows things down.

[@MickeyCuervo36]

Do you guys think you'd ever make a shield to go along with your swords? Or is that less of a concern with zombies?

[@zombietools]

We've prototyped a few, but nothing has taken yet. One day we hope to.

[@nodjr1595]

@@zombietools I cant imagine anything other than a buckler that can double as a knuckle duster being something thats small enough to make out of metal and keep the ZT style, but hybrids also arent your guy's thing.

[@gloving4hire]

@@nodjr1595hyrulian shield

[@Level5Fighter]

A round shield/targe of about 28/32 inches in diameter or a teardrop riding shield would be perfect. Perfect for holding doorways and keeping your hands and arms safe while in the street but small and light enough to sling over your back if you need to get away on say, a bike or motorcycle.

[@roberthowe3377]

An absolutely savage piece of kit and I take my hat off to all the craftsmen at ZT for their work, a definite must have for me in time to come.

[@robertosantinni9656]

I never would have thought they used a hand held grinder for the edges.

[@TheKing-dm3br]

Been wanting to see this one in action more! Good job!

[@archaicanarch5567]

You Gents are true artists and craftsmen. Bravo.

[@zombietools]

Thank you.

[@Neruomir]

I wonder if this should not be called carving a sword rather than forging. Considering its a process that solely removes material from a peace of flat bar rather than displacing and shaping the material.

[@nicholasmelvin7678]

This is remarkable. I've wanted a ZT blade my entire adult life, and i will be buying one next month knowing my money will be well spent. You are all so talented.

[@zombietools]

Thank you! What blade will you be getting?

[@FXR_Marine]

I’m DEFINITELY getting one from ZT. You guys know your shit. Outstanding video gents.

[@zombietools]

Thank you.

[@johnnysmall4206]

Very Nice Craftmanship!

[@traymann3929]

One of the best sword companies out there truly a work of art.

[@zombietools]

Thank you!

[@felis1977]

Great video! I love the scrap metal crotch armor :) I also like the mini Legionnaire sneak peek ;) I wish you made a Xiphos Scout with a regular Xiphos hilt as well - would be a perfect companion piece to my favourite sword.

[@JohnDoe-bw3tz]

Oh boy, now I want a Legionnaire... :(

[@dbzsuperfan711]

Every bone in my body wants to work a forge like this, absolutely beautiful stuff

[@KurNorock]

You guys ever think about doing a longsword? 42in blade, 12in grip, crossguard, pommel, 3-5 pounds, etc.. I'd probably buy one.

[@gloving4hire]

They working on guards now. I too would like to get rid of my crappy long sword for a zt one. But the leaf blade they have with a guard of any kind would be good enough for me

[@dogg92]

Look up the Battlecry Bosworth Longsword. Looks like something Zombietools would make and it's perfect for longsword stuff, like thrusting. Terrible cutter though. 3-5 lbs is insane though. That's greatsword territory.

[@KurNorock]

@dogg92 i said 3-5 because zombie tools tends to make things heavier. That being said, you'd be very hard pressed to find a 3 pound greatsword. Those are typically in the 5 to 7 pound range.

[@dogg92]

@@KurNorock Yeah I was going off of your 5lb suggestion, plus I rarely see a good fighting longsword over three pounds. They are meant for quick thrusting attacks moreso than slashing, which doesn't require a broad or heavy blade. I think I would actually hate a ZT longsword now that I think about it. Longsword techniques are fun because of the low weight/long reach of the sword. I could totally see them making an arming sword or greatsword though, but a ZT Greatsword would probably take a monstrous amount of strength to wield properly, lol.

[@KurNorock]

@dogg92 i wouldn't mind a 5lb longword as long as it's well balanced and on the longer side. That's why i specified a blade length of 42in instead of the 36in of the sword you recommended. A good balance can make a heavy sword feel lighter than it is.

[@raegune]

Great insight into the production process. Thanks for sharing!

[@njcranes]

I've always said that would be the best zombie slayer

[@roflswamp6]

This is literally everything i am looking for roman bit with Spanish celtic influence i absolutely need to get my hands on one

[@ericwilliams538]

Wow!!!! Using an angle grinder to grind out the shape of the sword is amazing!!!!

[@darthvaper6745]

Proper spring tempered steel..nice

[@TheBlacksmith5]

Awesome video guys, just ordered mine and cant wait for it. When yall came out with the Legionnaire i knew i had to have it. Just took me a few years longer than I thought it would

[@zombietools]

Awesome, thank you.

[@MASI_forging]

Such a great work. 👏👏

[@zombietools]

Thank you! Cheers!

[@ShooterMedic1818]

Best short sword yet.

[@thomaseskelsen1362]

Wow. Impressive blade by reputation. The team making it is superbly skilled. But honestly I wanted to say: what a great video. The sound design reminds me of Alien sometimes. Spooky and beautiful. Cheers 🎉 and Thank you 🙏

[@zombietools]

High praise. Thank you. The Alien vibe is accidental. However I do have a cat named Ripley, a cat named Bishop, a dog named Newt....and anther dog named Jonesy.

[@grandpaweber2097]

Very nice work, Gentlemen.

[@darthvaper6745]

Such a lot of work...so impressed

[@jeffreykoski2746]

Thank you for posting this!

[@roydmercer3731]

When do we get to see a video of the new CENTURION DAGGER? I’m so excited to see more, I’m convinced it will be my next Zombie Tools purchase!

[@zombieshoot4318]

Awesome. I have The Scyllis knife. It’s one of my favorites. I’ve been eyeing the Legionnaire for some time. I hope to get it sometime later this year.

[@MrMann703]

One day I hope to own one of your blades

[@chloehennessey6813]

I wanna get one so bad.

[@jr618]

Man, I'm so torn on getting this or the Apokatana next! I love your work!

[@CrownHetman]

Im curious if you guys will ever make warhammers?

[@zombietools]

Not yet....there is a prototype but nothing final and no end in sight.

[@p.s.9658]

As Celtiberian descendant, I LOVE IT!!!❤

[@calebsiebenaler7087]

Could you guys do a Spit making video next? Its the weapon i want most from you guys, juat need to find the money.

[@Maegnas99]

I really like the aluminium handles without the grip. I think it'd work quite well with just some raised areas or knurling perhaps.

[@zombietools]

Some people order the blades without the leather wrap.

[@kentsokay]

I ordered my Vakra as a bare blade and did my own micarta grips. it was fun and gave it my own flare, but the next blade I am getting from them I am doing complete, fwiw.

[@Scurvy_Soso]

Can't wait to get a piece from you guys, they all look stunning and from the reviews I've seen, these are tough!

[@Snakes-w1c]

It's people like these that are helping us prepare for the wars to come. You can bet the zombies will be ready. Will we?

[@christopheralbano7862]

30:48 End results Nice work 👏

[@camcam9691]

I Like your production step by step proces, you are faithful to every detail 👍 I love your Great Art and work discipline ♥️

[@zombietools]

Thank you! Cheers!

[@jeanmartox3570]

Sublime, et réconfortant de voir des artisans faire leurs passions!! Bravo de France!

[@jeanmartox3570]

Il y a du fan de Led Zepplin chez vos forgerons!!! Au vue des tatouages!! Excellent!

[@mortaljoe5647]

Sick sick sick.......all Hale ZT crew......love it all......my apokatana is hard to kill.....trying hard in a elegant way.....thank you for it.... hopefully something viking flavored in the future.😀😀😀

[@zadeify9596]

I know this is a crazy idea but have you ever considered greatswords? That would be rad.

[@zombietools]

We do have something great in the works...

[@trollunderbridge2292]

What I'd love to see is a bigger axe. Something shaped like the Kraken, but maybe about 4'-4.5'

[@oceaninks]

That new spear or custom spear looks sooooooooo badass❤

[@chrisken8902]

A work of art !!

[@TheSickjits]

I already knew all your blades were handmade, so I didn't question the price... but now that I see the worksmanship behind the blades, I feel like the price is too low. LMAO I gotta pick one up soon.

[@joefergerson5243]

Superb work and beautiful blades❤

[@zombietools]

Thanks.

[@ColdHarborOP]

I need one of those Centurion Daggers to compliment the Legionnaire I bought from you guys a couple years ago. How can I get my hands on one?

[@zombietools]

Available soon... Very soon.

[@madbull338hit8]

Blades worthy of the gods.

[@fishdude666ify]

First white guy besides me that I've seen use an angle grinder to do bevels, and not because you just don't have a 2x72 (which is my excuse). I've got a ways to go before i can do them as clean as that, but you've definitely given me some ideas for streamlining my process!

[@BUZZKILLJRJR]

Very good job, free hand beauty !

[@zombietools]

Thank you very much

[@clintwalker2045]

This slayed. You earned this subscribe. Now post one where you build the Apokatana!

[@zombietools]

Okay!

[@punkscrafty6513]

@zombietools would you guys consider making a rapier with a simple crossguard and a semi lengthy blade as a commission or as a new blade in your guys awesome line of weapons?

[@punkscrafty6513]

Something like alucards blade from Netflix's Castlevania animated series?

[@punkscrafty6513]

Well technically alucards sword would be an estoc but I was being vastly general as I don't expect an answer

[@smokeyou]

mine has a satin finish with brown leather handle.... love it and now i need the dagger.

[@justinfisher3827]

Cool how you set up to make the grind for the fullers

[@Sparhawk801]

By the way, what is that powder you sprinkle on when you etch the blade? I dont think I've seen that before.

[@zombietools]

It's aluminum dust from grinding the handles.

[@ZenDoggie]

beautiful work!

[@Jakoshdw]

If I had my choice from the Zombie Tools arsenal it'd be The Spit and a Legionnaire as a secondary. Considering my relative lack of sword training those seem the most intuitive... ya know "Pointy end goes into the other guy" 😂... but could still deliver a solid hack if a free target presented itself. Just need a Riot Shield to accompany to keep grabby hands and biters at bay. Seriously though... if had the liquid funds to drop a grand+ on weaponry this would be the purchase. Hope I get to that point soonish.

[@zombietools]

All good points. Good luck in "The Search for More Money." (Spaceballs 2)

[@bladetimeswissvladknives]

Awesome👍

[@zombietools]

Thank you! Cheers!

[@Sparhawk801]

That was a really cool and interesting process! Im surprised the heat treat is fine after all that grinding. I guess im probably over paranoid and dunk way too often.

[@jamesdeek7039]

The tests customers have done over the years show that the heat treatment is fine.

[@Sparhawk801]

@@jamesdeek7039 yeah, I believe it. I was just saying when I make a knife I'm constantly quenching it in water and it looks like I have been overly cautious because they really grind the heck out of them and their heat treat is fine.

[@andrewallason4530]

I figure, if I can touch the blade, I’m not going to ruin the temper, but, I still quench frequently, I guess like most guys. It also gives me a chance to look at the lines, and adjust my grinding, as necessary (or just admire my work 😝).

[@Sparhawk801]

@@andrewallason4530 same, I just need to get a heat gun and try to get a feel for how fast my blade is heating up at different grits. I usually dunk after every pass to be safe.

[@deathofkindness]

​@@Sparhawk801nothing wrong with that honestly..i do the same thing on smaller blades...I'm just starting to learn how to grind longer blades

[@VE061080]

Como faço pra adquirir uma Gladius dessas que vocês produzem?

[@zombietools]

zombietools.net/collections/blades/products/the-legionnaire

[@Martillo_de_Dios]

Damn!!I gots to get me one of them soon!! Love it!

[@leonardmelte3106]

Has anyone noticed the grip sort of looks like a Thor medallion?

[@kevinschantalle]

omg i need these!!!!

[@Biomass1]

Of course he's wearing a Black Label Society tee shirt, because makin blades is pretty damn metal. 🤟

[@samuelferrell9257]

I had no idea the Romans were so sophisticated!?

[@noneyabidness9644]

I make one sword a year...you guys make 100 a day. I feel so inadequate. 😂🤣🤣☺️

[@zombietools]

Better than no swords ever. Which is most people. 1 a year is just fine. Keep grinding.

[@soulstar4268]

Ever thought about trying a Khopesh? Would prob turn out sweet.

[@zombietools]

There are a few (very few) floating around the collectors market.

[@OfficialDiogenesofSinope]

Have you guys considered making a longsword?

[@iratezombiemann]

What I don't get is - why all the hate for zombies? What did we ever do to y'all?

[@zenhydra]

Nice try, zombie. You can't trick me that easily.

[@iratezombiemann]

@@zenhydra look bro just put the zombie tool down. we can talk about this

[@richardstrombergoverkill5099]

Do you know what zombies fear the most?....NECROPHILIACKS

[@andrewhull7296]

That's a sexy sword!

[@antonakesson]

Is there a type or style of sword you guys would love to adapt for Zombie Tools one day?

[@zombietools]

So many....

[@Soulcrushers666]

Do you make spear heads? Or other polearms such as halberds or lucerne hammers?

[@zombietools]

There are a few ideas on the drawing board, but have yet to yield fruit.

[@MQuinn-eb3zz]

Are you grinding out distal taper?

[@ajhearn4535]

that fullering jig is an awesome idea, any chance of seeing the making of a spit?

[@zombietools]

I'll take note. Thanks.

[@fliesinthesugarbowlshooflyshoo]

Will the big bad wolf ever gonna come back?

[@michaeltrimble7680]

The size of that oven!!

[@zombietools]

Why thank you.

[@upgrade1015]

So cool. Not a fan of the finish but hey , who the F am I , it’s not like I’m secretly Greg, Medford or anything

[@davids5203]

Why isn’t the executioner sword in stock

[@Sr_ECO]

That's from condor tool and company

[@vinterkriger]

I saw the Diphos, so you still make them? I want one so bad!!!!!!!!!!!!!!

[@zombietools]

Yes. zombietools.net/collections/blades/products/the-diphos

[@edgarhasbun5950]

sorry to ask but is that water you are using to.quench the hot sword? Aren't you Supposed to use some type of OIL? car oil or cooking oil?

[@zombietools]

It is quenching oil.

[@nodjr1595]

You can use oils or water, both work, they just do different things. Water cools the blade faster and makes it harder and more rigid letting you put a sharper edge on it. but can also severely warp or even crack the blade if you don't destress it properly, or just have bad luck. Oil cools the blade faster and makes the blade more flexible and able to take more of a beating, as well as lowering the chances of warping or fracturing.

[@StillNotLocal]

This looks awesome! Question at 25:43, what’s the powder stuff you put on the etching solution?

[@zombietools]

Aluminum dust, leftover from grinding the handles.

[@C_Franc2000]

preciosa obra de arte i love

[@intothewild3349]

Whats the point of balance ? I feel like having a full tang on such a short sword would throw the balance way off from where it should be .

[@zombietools]

About 2" up from the guard. About where the fuller starts.

[@StillNotLocal]

Great work! At 25:43 what’s the powder stuff you put on the etching acid?

[@zombietools]

Ground Aluminum.

[@gloving4hire]

Too bad nobody makes shields worth carrying, sometimes I think of bolting some iron 45 pound plates to hard wood. I can hold 2 together with my hands and on my knees press them at an incline angle for many reps. So a 90 pound kite shield would be light

[@zombietools]

Some day, we hope.

[@zenhydra]

Ummm...what? Assuming you aren't joking, why would you even want a 90+ pound shield? A traditional Roman scutum (a big-ass shield) was typically in the neighborhood of 14 pounds. And even if you wanted to make a ballistic shield, a kite style shield made of AR500 plates wouldn't even be close to 90 pounds. Remember, it's not about what you can lift, it's what you can effectively fight with. 90 pounds of extra mass is going to make even the strongest person move too slowly to be worth the defensive benefit.

[@zombietools]

A ZT shield yes. A 90 lb. shield, no.

[@gloving4hire]

@@zenhydra that’s true but I can dream of a shield that can just indestructible

[@gloving4hire]

@@zombietools deal

[@heylookabluejay]

Can y'all please make us Guts dragon slayer thanks 🙏😂 but maybe keep it at like 6' total length for "functionality" 😂😂

[@martinsmith9054]

Is there any distal taper on these blades?

[@dragoncutlery]

With the taper to the blade they have there will be some distal taper you can look at the fuller and notice that its wider near the guard than at the tip even tho it was originally the same depth thats the taper of the grind

[@natedizzah5877]

Do y'all do cutlery or just war

[@zombietools]

War!!!

[@prabuddhananaware8817]

will you accept the "make an indian khanda sword challenge"

[@elcas20012003]

nice job

[@zombietools]

Thanks!

[@jackaroni420]

It's worth 575.95$ on the website