First off, I've never played, or even seen the video game (nor do I want to), so I did a quick internet search looking for reference images. I found several images, each slightly different than the next, which makes it frustrating when you are trying to copy something. The "Pedestal of Time" seemed to be a very straight forward, angular stone shape, so I focused on finding reference images of the "Master Sword". Again, dozens and dozens of different images, each different than the next. I finally settled on copying this version
, since it appeared to be the easiest to duplicate with minimal materials and steps. And since it was really just a decoration for the cake (the stone portion is the actual cake) this image was best suited for the job.
Because the sword was to be inserted in the cake, an all plastic construction was the best way to go. 3/4" PVC was a good choice for the handle, so that is what set the overall scale of the sword. Using CAD (Autodesk Inventor is available to all TechShop members), I started with the dimensions of 3/4" PVC pipe (1.050" OD x 0.824" ID) and just 'eyeballed' the rest of the shapes and dimensions.
Not knowing the size of the stone cake portion yet, I set the length of the blade as long as would fit in the laser cutter. You may download our .DXF file here: http://www.lime3D.net/instructables/zelda.zip
Cut the pieces on the laser from 1/8" acrylic using the recommended settings.
Tip: Whenever making something from acrylic, and plan on painting it, use clear acrylic. This doesn't make any difference with the painting, but you will have more flexibility to use the scraps for other projects.