Introduction: How to Make Link's Ordon Sword

I've noticed a lot of people making Link's master sword, which makes sense. It's kind of THE Zelda sword. Recently, however, I was looking at some of the art on the Zelda: Twilight Princess game guide and realized that I really like the design of the Ordon sword. It's very simple but it has clean lines and is just a really nice looking sword. So I decided to make it my next sword prop.

Step 1: Supplies

For this project I used:
-A Board (scrap from a pallet)
-A Short Dowel Rod
-Wood Glue
-Spray Paint
-Brown Leather or fabric
-A Saw
-A Jigsaw
-A Drill
-A Router
-A Rasp and Files
-A Sander

Step 2: Design

Of course since the Ordon sword has already been designed this job is mostly done for us but there was a little problem of inconsistent detailing that I had to deal with. While looking for reference pictures I realized that the guard on the sword was drawn a couple different ways. Since they were both official artwork and therefore both correct I just picked the one that I liked the best. I also couldn't figure out what size it should be so I just kind of... guessed.

Even with the sword itself already designed I still had to decide how I wanted to build it. I decided to go with a basic flat sword blank that went from tip to pommel and add each element as individual pieces. So, after figuring out the shape I needed I drew it out on the board. I ended up making it a total of 42" long and 3" wide. Of the 42" I alotted 8" for the handle, 2" for the pommel, and 1.5" for the guard.

Step 3: Cutting Out the Sword

To cut out the sword blank I used a jigsaw. My board was the exact width I wanted so I just had to cut the tip, pommel, and handle out. If you're cutting your sword out of a wider board you might also want to use a circular saw or something else that is good for cutting long straight lines.

At this stage it looks kind of like a cricket bat. Let's see if we can't do something about that.


I used a router to give the blade its edge and then sanded it all down with a belt sander. The router bit I used was a 5/8" Chamfer bit. If you don't have a router you can use hand tools instead. It will definitely take longer but a good rasp should work.

Step 4: Cutting Out the Pommel and Guard

You can use any excess you trim off the sword for this part, but the board I'm using is a very hard wood and I had some other scrap that was much softer. So I'm using that since it will be easier to work with.

I traced the pommel from the main sword blank onto the other wood. I cut out the sides but left it attached to the board. Then I cut through the middle splitting it into two thinner pommels. Then I cut it off and gave it a good sanding.

For the guard I drew up a pattern for the top and then for the side and transferred it to the wood. I had to put two boards together to get the right thickness. I glued the two boards together with wood glue and clamped them tightly until it cured.

Once the glue was cured I drilled out the slot that the sword would fit into. Notice that I only drilled the hole wide enough for the pommel to fit through. I didn't want it to be able to slide down the blade. Then I used a small file to curve the inside edge down so it would rest against the rounded part of the sword blank. After I was happy with the inside I cut the shape out of the block.

Next came refining the shape. I used a straight saw and a coping saw to get the basic shape, then moved to a belt sander, and then finished by going over it with a file. After I was satisfied I did a test fit on the sword blank.

Step 5: Making the Grip

I wanted the grip to be round and thought the best way to achieve that would be to attach half of a dowel rod on each side. I'm no longer sure this was the best way to do this.

In order to do this I used a saw to split the dowl rod down the middle. If you choose to do it this way just make sure that you choose a dowel rod the same width as your handle.

Step 6: Putting It All Together

This step is pretty much just a matter of slathering everything with wood glue and clamping it together. Sort of.

First I slid the guard down and glued it in place. When I say "slid" what I really mean is "used a rubber mallet to pound it into place". I wanted a snug fit so I just kept filing the inside of the guard and sanding the handle down until it just fit. The I tried to gently pound it into place with the mallet. Once it was in place I squirted some glue into the wider end of the hole. It's honestly not glued that well but it can't slide back over the full handle so it doesn't matter.

After the guard I actually did the pommel next. I put some wood glue on either side and clamped the pommel pieces on.

After the pommel was dry I checked my handle pieces, trim off a little excess (that's why I did the pommel first) and glue them on.

Once everything was glued together I did some touch up stuff with my dremel. I shaped the edges of the pommel better so they would all match each other perfectly. I also added the detail to the pommel since I had forgotten to do that. It wasn't much of anything, just that little hole in the middle.

Step 7: Painting

To paint it I started with a basic spray paint primer. Give it a couple coats to cover the wood grain so it doesn't show through.

After the primer dried I gave it a couple coats of a hammered silver spray paint. I actually didn't want the hammered effect but I was trying to find a paint that would give the look of metal without that metallic fleck in it, because I've never seen a sword with metallic fleck in it. If you spray really lightly you can actually avoid the "hammered" look.

Step 8: Wrapping the Handle

This part is pretty easy. I had some scrap brown fabric around that I cut into a long strip. Pretty much just glue one end down and wrap it around until the handle is covered. Cut the excess off, put some glue on the end, and tuck it into itself.

I want to seal the fabric with something to keep it from fraying and to secure it better but I don't know if I can use glue without it being sticky. I know it would dry but would it react to sweat or the heat from my hand? If anyone has any suggestions I would love to hear them.

Step 9: The Finished Product

It's done!

Stand back and admire your work. Take it outside and swing it around a bit. Mount it somewhere for everyone to see. You are awesome. Pat yourself on the back. Then realize you don't have a scabbard to sling across your back like Link and run go make one.

Comments

author
Mr Sandwich (author)2015-05-26

Thanks

author
Mr Sandwich (author)2015-05-24

How sturdy?

author
The Rambler (author)Mr Sandwich2015-05-26

It's incredibly sturdy. Like you could seriously do some damage with this thing sturdy. As far as an exact curve goes do you mean the tip of the blade? I would recommend printing out a picture of the sword tip to scale and tracing it onto the wood. I think that would be about as exact as you could hope to get.

author
Mr Sandwich (author)2015-05-24

Exactly like the game

author
Mr Sandwich (author)2015-05-24

Also how would you go about making the curve if you want exact?

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broken bob (author)2014-06-23

ssswwweeettt

author
The Rambler (author)broken bob2014-06-24

Haha thanks!

author
jetpackbraggin (author)2013-11-03

I find Design Masters Modern Metals Champagne Silver (way too long of a name) gives a really nice metal like sheen if sprayed in thin coats. This write up really makes me want to make a Legend of Zelda sword.

author

Dooo iiit! Haha
I'll have to check that out. I really need to improve my painting skills as they are sadly lacking. I see such impressive stuff out there (yours included) and I'm just blown away by how real something can look with some skill and effort. I keep telling myself that if I get one of those trigger attachments for spray paint cans I'll instantly improve.

author

I've always wanted to try the trigger things. I have no idea if they make spraying easier or if they're just a waste.

author

For $2-3 I really should just pick one up, but as long as I don't I can blame my inadequate skills on not having one...

author
ihearmoosepeople (author)2013-08-31

I made a sword because of your post. It is a Finn sword from adventure time. I made an instructable on it. Thanks!

13, 11:40 AM.jpg
author

Wow, sorry for the late reply on this one. That looks awesome. I'll check it out.

author
16lundgcodm (author)2013-05-04

The square version is twilight princess: Ordon sword, the oval version (the one you made is skyward sword: training sword, so technically you made the wrong one.

author
The Rambler (author)16lundgcodm2013-05-04

The pictures in step two are from the official artwork on the Twilight Princess game guide. The in-game look of the sword is naturally more blocky but this doesn't take away from the fact that the version I made is most definitely the Ordon sword. The "Knight practice sword" from Skyward Sword is not a square version of this. It's completely different with a sort of "scoop" in the middle of the guard. Look at any of the cutscenes, screen captures, or official artwork and it will back me up.

author
16lundgcodm (author)The Rambler2013-05-05

Ok, i checked your right, maybe the oval version is from the gamecube version of the game, great job though. Try remaking it with a metal blade, and go hack at a tree 'til somebody starts to stare at you.

author
The Rambler (author)16lundgcodm2013-05-05

Haha, I'm sure the difference is probably due to the difference between the pixelated in game version and the cover art. Either way man, thanks for the compliment. Making a real sword is totally on my list of things I'd love to do!

author
MakeItWithJason (author)2013-04-30

Good work. Here's a sword I made. I wouldn't recommend mine for kids to make.

Make a Sword.png
author

Thanks. Cool sword. I've forged a knife out of a railroad spike before but never done anything of that size. I like the way you did the handle wrap.

author
TheRoyalJester (author)2013-04-30

great job..looks nice sadly i cant build one though

author

That's too bad, I'm sorry you've got whatever it is standing in your way. Thanks for the compliment though!

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Ringer1633 (author)2013-04-30

would a Dremel work instead of a router?

author
The Rambler (author)Ringer16332013-05-01

It might. Honestly there are probably several ways to arrive at the same result. Basically you just want to cut the "corners" off the wood so that it angles or slopes down on the sides. A dremel might work, though it would take a lot of time, and might not be consistent down the length of the blade since it would rely on the wielder having very precise movements. You can also use a rasp, a belt sander, a bench grinder, or even a hand saw (you'd just have to saw all the way down the blade on all four corners).

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