So I thought that a Peter Pan sword would be perfect for him. Just one problem, the disney version of Pan's sword is super lame. It's small and short and there just isn't anything inherently cool about it. So I decided to make the "Hook" version of peter's sword.
If you haven't seen Hook, it is an 1991 version of Peter Pan with Robin Willams and Dustin Hoffman. It's a great movie and I suggest you check it out of you haven't already.
So this is my "Hook" wooden sword made from walnut and complete with coconut guard. Thanks so much for looking and enjoy.
Step 1: What You Need
Router with cove bit
2 part epoxy
Step 2: General Shape
I started by planing it down so I would have a nice smooth canvas to start with. Then I used a cove bit on my router table to put a small grove down the center of the blade.
I used the table saw to take off the edges and cut the end at a point. I really just wanted to get a general shape. After you get that you can start with the finer details.
Step 3: Sanding
By the time I was done I had the wood so smooth and shiny that it could pass for steel. That might be a slight exaggeration...
After I got the general shape I was looking for it was time to move on the the coconut.
Step 4: Coconut
So this is one area that I am not familiar with. A few years back we took a trip to Jamaica and I was able to try a fresh coconut right off the tree. It was AWESOME! I ate way more than my share leaving very little for anyone else but I didn't care. This coconut was a different experience. I broke it open anticipating the firm white goodness that I had experienced some years ago but what I got was.... Not good.
So my question is, where should I look for a good tasting coconut, in the Midwest? Anyway, back to my ible.
The first step is to break it apart and cut out the edible part of the coconut. I used a chisel and a few good whacks to break it in half. After that you are left with just the shell. Using one half, I cut the bottom straight with my table same and started on the opening for the sword.
I used a dremel to cut the hole in the top of the shell. I started with a guess on the shape and then I would test for and widen the hole accordingly. You want to shell to fit tight.
Once I got the hole just about right, I fastened the shell to the sword with some hemp fiber. I mixed my two part epoxy and then soaked some of the hemp fibers in the epoxy. Then I wrapped it around the sword right over the coconut.
I let it dry for 24 hours and then I got to work sanding. It really looked cool sanded smooth. You could still see the individual strands of fiber wove in the epoxy.
Step 5: Finish
So here you are, a Non lame Peter Pan sword. The poly really made the walnut and the coconut stand out. It really turned out great and got a lot of attention. But the most important part of this whole build... My son thinks it's super cool. I thank you for reading this and I really hope that you enjoyed it. Let me know if you try one of these.