This is a big set of aluminum bladed cutlasses and hangers I made for the Colorado Shakespeare Festival’s 2012 production of Treasure Island.  CSF commissioned a set of swords with personality that were light, durable, and rang like bells. I built these swords out of a combination of 1/4” and 3/16” aluminum.  Most of the wider/fatter blades are 3/16” stock to help keep the weight way down.  Some of the skinny blades are 3/16”, some are 1/4”.  All the grips are super-glue sealed hardwood with swelling towards the rear to help keep a sure grip in the wind and weather at CSF’s outdoor theater.  The hilts are steel, some blued some not.  The swords are held together with a range of hardware.  Some have recessed pommel nuts, some have flange nuts that sit on top of the pommel cap.  The pommels caps are held in alignment with small brass colored nails.