The protagonist of the Nintendo Legend of Zelda games is Link, who's a sword-waving cross between Legolas and Indiana Jones. He runs around in a floppy hat solving puzzles and dispatching bad guys while trying to save the eponymous princess. My sons really enjoyed Twilight Princess and Skyward Sword, and were keen to get swords and shields so they could start pretending to hack apart hordes of minions in the back yard. This seemed a reasonable request, but making these safe AND strong enough to endure the depredations of two enthusiastic and energetic youngsters is not entirely trivial.
This instructable will show you how to make robust versions of Link's sword, a scabbard, replicas of his wooden shields, and fully functional slingshots. While this stuff is all part of a costume, it's also all quite tough enough to handle being bashed, scraped and abused in the course of a usual day's play.
Note: this instructable is four projects in one, so if I've blasted past something too quickly, post a question in the comments.