I recently rediscovered the versatility of paper mache for costume making at Halloween. With some paper, cardboard, white glue (also hot glue) and paint almost anything can be made; add some auto body filler and sandpaper and it goes to the next level.

I made a Witch King of Angmar costume for my daughter for Halloween but didn't take many pictures, but when I started making the sword I had the camera ready and here are the results.

Basic tools include:
  • hot glue gun
  • medical scissors
  • box cutting knife
  • sandpaper
  • paint brush or sponge

  • cardboard
  • chop sticks or wooden dowels
  • paper
  • white glue
  • hot glue sticks
  • white masking tape
  • urethane foam spray like for house insulation
  • acrylic paints and hammer metal spray paint

Step 1: Draw out a sword on a sheet of cardboard

Draw out a full outline of the sword blade on a large sheet of cardboard. Use a box cutter blade or something similar to carefully cut out the blade outline.The cross-guard is drawn separately and the handle is a piece of PVC pipe cut to length. Use a hack saw to cut a grove into the end of the pipe and hot glue the "blade" into the grove as shown in the picture. 
I like that you used an unconventional material to make a conventional sword. Well done!
Same technique, different prop. I made a staff for Yuna from Final Fantasy X. I am also making Auron's sword and will post those pics when its done! :)
<p>Cosplay is awesome! Thanks for the pic.</p>
<p>I used your techniques to make a dagger. Thanks Robbotberfest!</p>
<p>Wow I never would have believed that was made out of paper mache! Excellent idea and Instructable!</p>
everyone was complementing me on how wonderful my sword looked
Awesomeness! Thanks for the picture.
Thank you so much for posting this. It helped me make a She-Ra Sword of Protection and a Xena Chakram for Sydnova. I also made my 5 year old a knight's sword. So much fun!
Wow!!! Thanks for posting your pics, they look great.
Thanks for the easy to follow tips! Never dreamed I could create such awesome props! :)
<p>Fantastic! Looks like an actual sword in the photo!</p>
<p>Wow looks like real. Thank you.</p>
Very impressive. Paint job is sensational
<p>Love the costume, so good it looks real.</p>
<p>this is awesome but i dont read the newspaper... no papier mache :(</p>
thats really cool thanks for the idea
<p>Amazing job! Using the hot glue for bringing out the raised detail is a great idea and the mixture of paints at the end works very well. How is the sword bearing up a while down the line?</p>
so helpful ill use this for my Ezio costume thnxx
Nice job dude! You really have art skills!
Also what size of PVC pipe?
Where did you find the urethane spray?
Please let me know where you got that spray paint and what brand it is if you would be so kind.
I bought the Rust-Oleum hammered metal paint at Walmart and used light grey and black acrylic paint applied with a sponge. <br> <br> http://www.rustoleum.com/product-catalog/consumer-brands/universal/universal-hammered-spray-paint
Thank you I appreciate it.<br>
Actually it's Krylon Fusion hammered metal; I just double checked. Either should work though.
Really good this. Well done. Very creative and I'm sure your kids must love you for your inventiveness.
Great idea. I love the sword. The ingenuity of people on this site never fails to amaze me.
I really like the sword looks great, I helped my friend make a similar costume but I used leather for the gloves (don't recommend it) I'd love to try making a sword like this one though cause the metal one we have is kinda heavy, and we don't have a morgul blade. So using something like this I think I could create a very good replica and starting small might be easier anyway.
Wonderful! I'm a firm believer in the power of cardboard.
Well done! The best part is that it is inexpensive and looks great!
That's my favorite part, the whole thing cost less than $2.
that looks AWESOME ! !
Bookmarking this for next Halloween. Thanks.
Totally realistic! Love it!
Awesome! Looks totally real! <br>
Wow...good enough to knight a Knight at night...{O..O}.....
Exceptionally well done! So impressed. If I was wearing a hat, I'd take it off for you.
Awesome. I continue to underestimate the power of paper mache.
I'm lovin' it. It's steampunk gear next :) <br>
Oooo, sounds cool. Anything specific in mind yet, or just kind of &quot;steampunk, go!&quot;?
A nice top hat would be a good start and some kind of arm and shoulder prosthetic. Next Halloween.....
Very cool, if you're thinking of using leather for your top hat allow me to toot my own horn and point out that if you check out my instructables I have written one on the subject. It's a bit stylised but the method should be fairly universal.
Wow, this is fantastic. It looks great, and gives me some ideas for next years Haunted Library. Thanks for the tutorial. (Costume is excellent, too. )
Thanks <br>
That is the most non-paper looking paper sword ever!
Thanks, it's very simple and fast to make too.

About This Instructable


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Bio: Dad and hubby, paleo food enthusiast, solar energy, boating, making stuff, melting stuff, and raising chickens.
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