Step 1: Step 1: How to make the blade

Picture of Step 1: How to make the blade
The blades are best made from a hardwood. I used white oak, but you could use maple, ash, cherry, red oak, etc.
Rip a piece 1 3/4" x 1" x whatever length you desire (I ripped 48" pieces and later cut them down to 24").

When you've cut all your pieces (if you're making more than one sword) change the angle on the tablesaw to approximately 15 degrees.

You will be making four (4) rips.

Follow along with the picture (crude, I know).
1st cut will give you your first bevel. It should be exactly in the middle for the part of the sword blade in the air, and slightly past the middle for the part of the sword blade resting on the table.
The idea is to get a crisp bevel on what will be the side of the blade and a small (1/8") flat spot on the "edge" of the blade. Less chance of a horrific injury when the kids are playing with the swords later. For the purpose of clarity we'll call the end now towards you "A" and the end that will be cut first "B".
For the 2nd cut, flip the piece so that the 1st cut is up and towards the fence. "A" is towards you.
For the 3rd cut you will flip the piece end-to-end so that "A" will now be cut first and "B" is towards you. 1st cut is still up, but away from the fence.
For the 4th (and last) cut, flip the piece so that the 1st cut is down towards the table and against the fence. You may have to adjust the fence a small amount so that the cut matches the other side.

You now have a sword blank. Cut it to the desired size.
lotrsam115 years ago
Hey! awesome instructable! i was wondering, since i dont have a table saw with an easy way to cut wood at an angle, do you think it might be possible to try to use a hand plane for shaping out the sides of the blade? thank you!
BobbyMike (author)  lotrsam115 years ago
You definitely could. You might also look at using a drawknife. http://en.wikipedia.org/wiki/Drawknife

My kids love to make them themselves with softer wood. You can find white pine or other soft woods a Lowes or Home Depot. They use a sander for form the blade themself. It's definitely not as nice or refined as using a table saw to form the angles, but they really enjoy doing it themselves. If you have a belt sander you can turn it upside down and sit it on a bench to make a steady sanding surface. The softer woods don't hold up as well, but they love making new ones anyway.

BobbyMike (author)  drodge1 year ago

Neat way to get your kids involved in making things!