This is how you make a very simple buster sword in a day if you have all the materials. This is my first instructable and I worked hard to make it. So please don't criticize me. Read entire set of directions before starting. my sword had a blade that was 82 inches tall, a hilt at 1 1/2 inches, and a handle at 11 inches. So in total my sword was 7 feet 10 1/2 inches tall but it can be shorter to fit a Halloween costume or something (actually it is recomended that it be anywhere from 3 to 6 feet). Put any suggestions in the comments and please give this a five star rating.
Step 1: materials and work space
Now you are going to need:
Nails (or screws if you would like to)
Thick dowel (I used 1 1/8 inch dowel)
Drill bit matching your dowel
Glue (I used gorilla glue but you can use wood glue)
wood (Desirably 3/4 inch high 5 1/2 inch wide and another at 3 3/8 wide by 1 1/2 inch high)
something to prop wood up on
saw (table or hand held you decide)
Paint ( if desired)
Tape measure (if you like to be exact)
Step 2: Starting off
We are starting with the area in the picture. Since I used gorilla glue I don't know the drying time of wood glue but what you need to do is use drill and drill bit to make a hole through your hilt part in the middle. Drill through about half way and then insert plenty of glue and then dowel. Cut the top of the thinner wood to a desirable height and point. wait until glue is strong before you pick it up. To test this poke glue with tooth pick.
Step 3: Glueing the blade
After the handle dries prop up the blade so it is at the level on the hilt that you want. Then put glue on the bottom of the blade. put it against the hilt which I would also recommend propping up. wait until glue is strong it does not have to be absolutely dry.
Step 4: Nailing for security
Use nails (I used 6. 3 on each side of the hilt) to put blade in a secure position nail in the handle by nailing through the wood on the side of the hilt. For extra security put nails in the wedge that the gorilla glue creates around the handle.
Step 5: Final touches and Congratulations
Using the drill create two holes at the lower part of the blade. Paint if desired and cut handle to desired shape if you would like. You have a Buster Sword. If you would like to put screws in the handle for design you can.