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A few weeks ago my son broke his favorite sword. It's one of those plastic numbers that lights up and makes all kinds of noise. I fixed it with some CA glue, and then whilst slaying dragons and rescuing princesses in our back yard, he broke it again in another spot.

I figured it was time to make him a sword he couldn't break. Something timeless that he could even give to his own son one day. So today, we're going to make a wooden sword out of Maple and Walnut.

It consists of three parts. The pommel and cross guard are made from Black Walnut. And the blade and grip are one continuous piece of maple. The cross guard has a through mortise allowing the grip to slide through. And the pommel has a mortise to accept the bottom of the grip.

Let's take a look at the template I drew after I made this thing, and how I made it.

Step 1: The Template, Materials & Tools.

The images I have attached aren't to scale, they are just for reference. If you want scaled drawings, download the PDF's. If you print them on 8.5 x11.0 (215.9 by 279.4 mm) paper, they should scale right.

The Materials

This one's pretty simple, I used things I had lying around. But of course, you can use whatever you'd like.

  • Maple for the blade and grip.
  • Walnut for the pommel and cross guard.
  • Wood Glue to hold the wooden sword together.

The Tools I Used

In order of appearance, of course.

  • A whole lotta love.
  • Table saw
  • Cross cut sled
  • Band saw
  • Thickness planer
  • Measuring tape
  • Pencil
  • Straight edge
  • Combination square
  • Benchtop belt/disc sander
  • Router table
  • 45° Chamfer router bit
  • F-style clamps
  • A sharp knife
  • Very sharp 1/2" chisel
  • Carvers mallet

And now for the fun stuff, let's make this thing!

Nice work, looks very sturdy
<p>I have made a couple of wood swords as well. They are always a lot of fun. This one is beautiful.</p>
<p>Thanks! I was really happy with how tight the joinery came out. I need to get a better camera so I can show more of the detail. Cool measuring tape you did the other day, by the way. </p>

About This Instructable

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Bio: I'm a husband, dad, contractor, woodworker, tinkerer and all around busy dude. That said, I put projects out when I can. A weekly basis ... More »
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