Okay so it's not literally forging because it's made from wood, but it sounds better then making.
I've been meaning to write this Instructable for almost a year after completing my Master Sword back in May 2009, but things have always seemed to get in the way until now.

I've always been a great fan of all of the Zelda games and I knew it was only time before I attempted to make a replica from one of the games.

So in this tutorial I will be showing you the steps I took to produce my Master Sword. I've gone for the sword from Twilight Princess as it's the most detailed Master Sword to date and it looks the best.

Update 27th May 2011
I've begun work on the Hylian Shield. You can follow my progress on my website http://www.jonsprojects.co.uk
I will be creating an Instructable when it's complete.

Step 1: Tools and materials

Sand paper
Sanding blocks
Files and rasps
Set square
Coping saw
Drill with various bits
Craft knife
Dremel (rotary tool) with various bits
Clamps (and lots of them)

Wood glue
Wood filler
Pine strip wood
Spray paint
Enamel paint

<p>Great tutorial. I used the plans you made and was able to make my own out of steel and cast aluminium. </p>
<p>hey buddy, would you be willing to share those plans?</p>
<p>Nice work mate looks great</p>
<p>That's not forging, it's whittling. Accomplished whittling, but whittling nonetheless.</p>
<p>So are you going to be making a tutorial on the Scabbard?</p>
<p>This is really awesome! I'm going to have to try it myself once I start my Link Cosplay!<br><br>On a side note, do you have a instructable for the Scabbard? Also, do you know if the sword is Con safe or not? Thanks!</p>
<p>will u sell that one im interested if so im a big fan of zelda</p>
<p>link's master sword in the twilight princess is purple not blue, but good job on it looks good :D</p>
<p>If you look closer, especially those two photos from the painting process taken with a flash on: it is exactly that bluish purple it's supposed to be, it's even metallic! The blue tone is due to this colour being one of the most troubling colours to take proper photos of, especially with cheaper digital cameras. In neon light, it's purple, in sunlight or without flash, blue. It's the same issue with bright red, whether it'd be paint, fabric or wigs. Wavelength of the light reflected by the object, I just say...</p>
<p>Hey! (Listen! *lol*)</p><p>Firtst of all, thanks for the tutorial! You did some amazing work there!<br><br>The only thing I wonder is whether you can easily pull it out/stick it in when you wear scabbard? That's something that always troubled me ever since I saw Link doing this awsome swinging and - bam! Though the lenght just wouldn't allow him to. You know what I mean? Physically impossible. So, in case you managed to, how long is your arm from the middle of your armpit to the middle of your palm?</p><p><br>Greetings, Ilionej =)</p>
Can you please make one of the scabbard because I think it looks awesome
How long would it take to make?
<p>im thinkin make a metal blade piece</p>
It's very good u should make a shieth tutorial
<p>Man this is amazing!</p>
<p>He man are you planing on adding a tutorial on how you did the scabbard? because It would be really helpful!</p>
I love the detailing. Could you by any chance, give me the Imperial measurement for the wood?
How did you make the scabbard?
<p>I can't read the deminsions on the drawing :/</p>
<p>How come you didn't add the winged hand guard to the blade piece? When you glued on 2 other handles/hand guards to the top and bottom there was an empty space in the middle. Why did you make that separate from the blade? </p>
<p>How much to sell it for?</p>
<p>I'm going to be using this tutorial to make myself a sword for next years Anime Central in Chicago, but I'm wondering what you used the basswood for. Its one of the materials listed and i didn't see it used. also what was the thickness of string that you used? Thanks</p>
<p>The basswood was used for the Triforce detailing on the blade.</p><p>The string was probably about 2mm thick.</p>
<p>I proudly present you my version. I even made the matching hyrule shield.</p><p>Your instructions and espscially the dimensions helped me a lot, thank you! Mine might not be as perfekt as yours, but I'm fully satisfied with the outcome. You can't expect more when you rush through the whole process in only 6 days, I had to get my costume ready for use. :P Unfortunatly I had to carry it while the paint wasn't fully dried, so some blue of the guard went off.</p><p>Origionally I planed to paint the blade and handle as well, but I thought it would be a shame to cover the nice acorn blade with any paint. I left the handle blank for a better feeling while holding it. I might add a pommel as soon as I have some spare time, but untill then it stays as it is. Appart form that all changes are minimal.</p><p>Both, the sword and the shield are base on an arwork from the official Hyrule Historia. For the shield I roughly trace out the pattern on paper by hand (upscaled by ~10x), transfered the individual pieces on wood with different thicknes, cut the parts out and finished them with a dremel, files and sandpaper. The inner parts are coated with 2-3 layers of primer, than either a layer of silver paint or two layers of acrylic paint with a gloss finish. The outer ring was first glued to the board in order to sand level the edge. Primer was applied over the whole board exept the places where the other pieces went later. I masked the ring to paint the inner parts blue, later I did it other way around for the silver. Unfortunatly the blue wasn't completly dry so some stuck at the mask. The shield can be hold by two stripes of artificial leather hot glued to the back (nothing fancy, so no picture).</p><p>The only thing left to say is that ist was definitly worth all the efforts I put in it, it looks and feels amazing to hold it.</p><p>Today the Master Sword, tomorrow Hyrule :D</p>
Hi man, awesome job. I don't know if you're still answering this but I have a related question. All I could find in town was pine stripes with 1.4 cm. thickness. Which would be the best way to take it down to 1 cm. like yours? Maybe saw it then sand it? It's 4 mm. not much margin there. <br>Thanks! The tutorial is amazing!
<p>Run it through a thickness plane - or plane it by hand.</p><p>In all honesty though - it would be easier to find the right size board or find two 0.5cm boards and laminate them together with wood (PVA) glue.</p>
<p>oops - just noticed this was 4 months old!</p>
I started making one but the blade was too thick for the handle so it wouldn't stick, what do I do
Would be good to see a picture of what you mean.<br><br>My blade and handle were made from one piece. The handle was then built up so I never encountered this issue.
<p>I'm curious. Do you actually mean 5mm board? That seems incredibly <br>thin. Could it be that you meant 5 cm board, with a total width of 10 <br>cm?</p><p>Fantastic job by the way. Making one myself, which is why I ask about the thickness. You wouldn't happen to have the dimensions (interior and exterior) for the sheath would you? </p>
<p>Think you might be mixing up thickness with width.</p><p>If it was a 5cm thick board you'd end up with a fence post as a the blade.</p>
If you make the shield then you should do 3 layers. It would go cardboard,wood,cardboard
I meant to say I'm
Sorry l wrote LM
I think LM. Just gonna use ribbon
Im gonna try making one my self
<p>Go for it!</p>
What did you use for the stripes on the handle?:D
The stripes are made from cut up tennis racket strapping.
Outstanding job!
When will you create instructions for the scabbard and shield
sorry I accidentally posted my last comment 3 times
I know this might sound like a hard long project but can you make instructions on how to make the sword out of metal please
I know this might sound like a hard long project but can you make instructions on how to make the sword out of metal please
I know this might sound like a hard long project but can you make instructions on how to make the sword out of metal please
what color paints did you use for the sword?
Make an instructable for the scabbard too!!!
Dude! That's SICK!!!!!
how much do they cost?
You could easily make replicas of your sword without lifting a finger. If people were really interested you should look into having them machined. They can make it out of any material you wanted, resin, plastic, metal, etc. Way less than $60 a piece.

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