The adopted method of making it, from the Arabic ... 'exca' as in to remove by smashing the clay cast/mold ... & 'ca - libre' as in the type of mold/cast that is wrapped around the blade part of the handle & the handle part of the blade in order to directly cast/mold & sort of weld the hilt & hand guard directly to the sword ... this tight fit measuring is also where we get the word that applies to bullet size that must be a very close & tight fit for the gun ... 'calibre' ...

1) "Excalibur King Arthur's sword, c.1300, from O.Fr. Escalibor, corruption of Caliburn, in Geoffrey of Monmouth (c.1140) Caliburnus, probably a variant of the legendary Ir. sword name Caladbolg, which may be lit. "hard-belly," i.e. "voracious."" Source and further information: http://www.etymonline.com/index.php?term=Excalibur 2) "The name Excalibur apparently derives ultimately from the Welsh Caledfwlch which combines the elements caled ("battle, hard"), and bwlch ("breach, gap, notch"). Geoffrey of Monmouth Latinised this to Caliburnus, the name of Arthur's sword in his 12th-century work Historia Regum Britanniae. Caliburnus or Caliburn became Excalibur, Escalibor, and other variations when the Arthurian legend entered into French literature. Caledfwlch appears in several early Welsh works, including the poem Preiddeu Annwfn and the prose tale Culhwch and Olwen, a work associated with the Mabinogion and written perhaps around 1100. The name was later used in Welsh adaptations of foreign material such as the Bruts, which were based on Geoffrey. It is often considered to be related to the phonetically similar Caladbolg, a sword borne by several figures from Irish mythology, although a borrowing of Caledfwlch from Irish Caladbolg has been considered unlikely by Rachel Bromwich and D. Simon Evans. They suggest instead that both names "may have similarly arisen at a very early date as generic names for a sword"; this sword then became exclusively the property of Arthur in the British tradition. Most Celticists consider Geoffrey's Caliburnus to be derivative of a lost Old Welsh text in which bwlch had not yet been lenited to fwlch. In Old French sources this then became Escalibor, Excalibor and finally the familiar Excalibur." "In Welsh legend, Arthur's sword is known as Caledfwlch. In Culhwch and Olwen, it is one of Arthur's most valuable possessions and is used by Arthur's warrior Llenlleawg the Irishman to kill the Irish king Diwrnach while stealing his magical cauldron. Caledfwlch is thought to derive from the legendary Irish weapon Caladbolg, the lightning sword of Fergus mac Roich. Caladbolg was also known for its incredible power and was carried by some of Ireland's greatest heroes." "Caliburn to Excalibur Geoffrey of Monmouth's History of the Kings of Britain is the first non-Welsh source to speak of the sword. Geoffrey says the sword was forged in Avalon and Latinises the name "Caledfwlch" to Caliburn or Caliburnus meaning steel. When his influential pseudo-history made it to Continental Europe, writers altered the name further until it became Excalibur which is a derivation of the latin phrase Ex Calce Liberatus or when translated Liberated from the Stone. The legend was expanded upon in the Vulgate Cycle, also known as the Lancelot-Grail Cycle, and in the Post-Vulgate Cycle which emerged in its wake. Both included the work known as the Prose Merlin, but the Post-Vulgate authors left out the Merlin Continuation from the earlier cycle, choosing to add an original account of Arthur's early days including a new origin for Excalibur." Source and further information: http://en.wikipedia.org/wiki/Excalibur