Excalibur is non-replicable in that it can't be perfectly reproduced. Archer himself admitted it can't be perfectly copied and that he could only "get it close". I'm assuming the sword Shirou projected at the end of HF was also just a poor knock-off of Excalibur. It's still very powerful, but it's not a divine sword.
Basically, it's more or less the same as his projection of Kansho and Bakuya, whose originals are uber powerful compared to the one Archer uses.
Quote:
Complete Material 3: Q: If the original Kansho and Bakuya take the stage in the Holy Grail War, as the twin swords reaching the realm of Gods due to the sacrifice of human lives, will they possess powers as Noble Phantasms? Or, since they did not have wielders in the legend, thus cannot become Noble Phantasms?
A: Absolutely without a doubt that they will be true Noble Phantasms. They will be extremely strong anti-monster Noble Phantasms. Rider's ultimate form--Gorgon Lv100, or the extra-dimensional evil god summoned by Gilles, will all be cut down in a single strike.
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