Forging Links Master Sword - Twilight Princess version

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
I will be creating an Instructable when it's complete.
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Step 1: Tools and materials

Picture of 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

Step 2: Design

Picture of Design
So the first step in any good project has to be design.
After lots and lots of research I came up with the design I wanted to go for. Using lots of reference pics I drew a scale picture.
Using the attached picture in this step you can see the dimensions I used for each part.

After a few comments I've found the original photo of the plans, tidied them up a bit and uploaded them to some of my web space. Links below.
nqtronix made it!4 days ago

I proudly present you my version. I even made the matching hyrule shield.

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.

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.

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).

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.

Today the Master Sword, tomorrow Hyrule :D

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azayas14 months ago
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.
Thanks! The tutorial is amazing!

Run it through a thickness plane - or plane it by hand.

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.

oops - just noticed this was 4 months old!

Jake156225 days ago
I started making one but the blade was too thick for the handle so it wouldn't stick, what do I do
Jonny1983 (author)  Jake156225 days ago
Would be good to see a picture of what you mean.

My blade and handle were made from one piece. The handle was then built up so I never encountered this issue.
Roen1061 month ago

I'm curious. Do you actually mean 5mm board? That seems incredibly
thin. Could it be that you meant 5 cm board, with a total width of 10

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?

Jonny1983 (author)  Roen10626 days ago

Think you might be mixing up thickness with width.

If it was a 5cm thick board you'd end up with a fence post as a the blade.

natedoddle2 months ago
If you make the shield then you should do 3 layers. It would go cardboard,wood,cardboard
natedoddle2 months ago
I meant to say I'm
natedoddle2 months ago
Sorry l wrote LM
natedoddle2 months ago
I think LM. Just gonna use ribbon
natedoddle2 months ago
Im gonna try making one my self
Jonny1983 (author)  natedoddle2 months ago

Go for it!

natedoddle2 months ago
What did you use for the stripes on the handle?:D
Jonny1983 (author)  natedoddle2 months ago
The stripes are made from cut up tennis racket strapping.
DaveNJ4 months ago
Outstanding job!
patbking5 months ago
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
dragoon150910 months ago
what color paints did you use for the sword?
16lundgcodm11 months ago
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.
Jonny1983 (author)  burning_empire1 year ago
What sort of company would I need to find to do that? I'll see if I can find one in the UK.
I don't know anything about companies that do that, but if you still have the sword you could use it to make a mold and then use the mold to make copies. They would still have to be painted but that could be a pretty easy way to duplicate and sell them.
Actually the UK is the central hub for effects shops, and movie companies that fabricate props and practical effects.

You can look up local CNC machine shops.
Dylan971 year ago
Hey man you did great quick question how did you make the diamond
fozzy131 year ago
I like what you did with the Intro picture.
Nick705871 year ago
This is awesome.. I've always wanted to make a decorative Master Sword (from Ocarina) and Hyrulian shield to hang in my gaming area. You have inspired me to give it a try. Good work.
Jonny1983 (author)  Nick705871 year ago
Yeah, I plan on doing that once I complete the shield. Have the sword behind the shield going diagonally.
Maybe some lights mounted behind to may it appear to glow :D
megaduty1 year ago
Well done! This is an important ible because "Its dangerous to go alone".
Jonny1983 (author)  megaduty1 year ago
You never know what bad guys you'll run into :D
That is awesome! Wonderful job and amazing details!
Jonny1983 (author)  Penolopy Bulnick1 year ago
Thanks a lot, I'll be putting up a Hylian Shield one once it's done.
You gotta have a complete set ;)
Now all you have to do is take it to a CNC machine shop and have them make replicas for you. You are on your way to having a fun and great business
makendo1 year ago
Great work! If you shaped the handle with rasp alone, you have a great eye and real patience, kudos. Thanks for the plans and all the build details.

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