Historically Accurate Sword of Gryffindor (Harry Potter Series)

[d_jedi1]

I can think of historical examples where metals were used and others where wood might have been clad, so whatever you go with, it'll look amazing and I'm on-board.

 

[Inquisitor Peregrinus]

Depending on how deep your pockets/how committed you are to the project, Shapeways can 3D print things in silver or gold or steel or like that. Do all the design work and get the finished bits you can assemble and put gems in and whatever other finishing work it warrants. As for how they would have made something like that a thousand years ago... Magic.