Two 3/4-by-1-1/2 inch white oak or maples, cut 42 inches long
Planer or sand paper
Step 2: Make the Blade
Join the 2 pieces of wood together on their 1-1/2-inch sides with wood glue. Coat the wood with wood glue so they are connected all the way down the blade. Clamp the wood together until it dries. Let it dry for about 4 hours. Remove any excess glue around the edges.
Step 3: Sand the Edges
Plane or sand the wood until you have a 1/8-inch bow in the center of the board. Cut the sides of the boards down to 1 1/8 inch. Plane or sand the Bokken until the sides are smooth.
Step 4: Make the edge on the blade
Cut the sides and ends of the sword with the router to make a 1/2-inch round edge.
Step 5: Angle the Blade
Use the chisel to angle the end of the blade to 45 degrees. Sand the rough edges until the wood is smooth.
Step 6: Stain and Let Dry
Apply 2 coats of stain and allow it to dry. If there are any rough edges after the first coat of stain, sand them down before applying the second coat.