Picture of Metal Sword (of Doom)
Have you ever wanted to have a nice sword? I have. Now you say, "Why don't you just go buy a plastic or wood one from Walmart?" Because the plastic ones break and the wood ones do too, not to mention they're made in China, which means the workers are underpaid, they probably have lead paint, and they're just plain crappy. You can make a good quality wood one yourself, which I have done, and it works, but I've always wanted a metal one. So I finally decided I couldn't wait any longer so here it is!

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Step 1: Tools

Picture of Tools
~Something to hammer on, like a piece of wood
~Cinder block or some raised object, if you want your sword curved
~Sandpaper 100 grit or more
~Hacksaw blade, preferably one for cutting metal
~Hacksaw handle


Step 2: Materials

Picture of Materials
|---------Sword stuff----------|
~1 10' piece of 1/2 inch metal conduit -$2 at lowes

|---------Handle stuff---------|
~Thick stiff leather -I had it lying around -$7 at craft store and you'll have alot left over
~Thin leather -I had it lying around
~gorilla glue or pine sap if you want it to be old timey -I had it lying around -$3 for bottle
~some sort of cord, I used hemp -I had it lying around -$3 at craft store

|-----Total for everything-----|
~$15 with a lot left over

Step 3: Cut it up (Muhaha)

Picture of Cut it up (Muhaha)
Tools needed
~Hacksaw blade
~Hacksaw handle
~High-performance piece of moldy wood

Materials needed
~Metal conduit

You want to cut it the height from the ground to your bellybutton so if you hang it from your belt loop it won't drag on the ground. My hacksaw handle didn't show up so I had to use my hand. It will take 2-5 minutes with a handle and 5-15 minutes without a handle (like me). Then sand both ends with your sandpaper until it's nice & smooth.
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"Sword" this is bullsh*t.
beall3 years ago
if you wanted a metal sword you can buy one off the internet. I got a really nice one at website called swords 4 samuri
cobalt4204 years ago
whats a conduit?
Sylkhr (author)  cobalt4204 years ago
Conduit is used to house wires. It keeps them from being cut or mangled.

thanks heared of it but never new what it was.
Nesbitt114 years ago
You sound like a funny guy, but i have to tell you that unless you pressure welded the sides of pipe together (and even if you did) it would break or bend in a fight. Especially if that metal aluminum? You should go for either a mild steel or iron bar or a strip. That way its easy to shape but you can make it stronger by tempering.
i made one but i used a 3/4 of an inch thik conduit.
nikolardo4 years ago
I have done something similar in the past, but had forgotten about it.  Thank you for reminding me in such eloquent language!

Possibly helpful tidbit:  one source for the "metal conduit" is ski poles, especially ye olde ancient aluminum ski poles, which can be very long.  It is quite easy to remove the paint; I use a bench grinder with a wire brush on it, but a high performance wire brush (with handle) or sandpaper would probably do the trick too.
tyldob5 years ago
This is honestly amazing! Just what I was looking for! I was planning to make a movie but I'm in Britain, and there are veeeerrryyy strict weapons laws in the UK. I may make some adjustments to your original plan but still thanks for the amazing instruction lol XD
Kaiven5 years ago
Is conduit aluminum?
if not, it's close.
I've started to make this, but with a wood handle and flat stainless steel blade! Almost finished
limpach6 years ago
I will give you credit good idea for a play sword but don't insult sword making by calling a smashed metal pipe high quality
Maybe you should research what swords were actually used for when invented. They were not made to gloriously hack enemies in to pieces with a few swings, like the movies often portray. The first swords in many areas were made of bronze, and although a blade like edge could be applied, they were hardly good for cutting. They applied blunt force trauma wounds when used, breaking bones. Much like their brother the mace. In lieu of this, a metal pipe hammered down to give less wind resistance when swung properly, is a nice representation of the aforementioned. It is no insult to think of different materials or paths to use when making something that is already widely used, that's how we humans are to the point we are now.
True of many swords across history, for sure, especially in eras in with lots of armor. A bronze-age short-sword wouldn't hold an edge for very long during "intense use" . Scottish claymores, along with many of the more ornamental African swords or Aztec war clubs with obsidian blades mounted down the sides  would also be good examples of this kind of weapon.

The katana, tho, would not be. And that's what this sword is clearly modeled after.They were designed for cutting. Folded steel blades stay sharp as the layers of softer steel wear away faster than the harder steel, creatiting a virtual microscopic sawtooth. The martial arts which use them are all centered around powerful cutting strikes and practice. They were owned by high-ranking members of society (especially in times where they forbade swords to lower classes), and saw a lot of upkeep. This weapon was not a bludgeon.

Pounding conduit into a sword is a really neat idea, and gives a nice effect. But if you're going to call it "high-quality", it'd be nice if it were at least solid and had no hollow bits.This is without a doubt the coolest toy sword I've seen in a long time, but as for a real sword you'd probably still be better off with a leaf spring.
i said it was i good idea. I just don't think it right to call it high quality.
Sylkhr (author)  limpach6 years ago
Well, it actually is alot higher quality the anything you'd buy in non-specialty store.
Camisado Sylkhr6 years ago
Not really. A low quality forged blade is still better than a smashed pipe. Although your idea is good, I stand by limpach that it's not right to call it high quality.
Juklop Camisado6 years ago
I think he's comparing it to the 20 dollar crap you find on websites. These smashed pipes are better than those Stainless steel machine-made stuff.
Camisado Juklop5 years ago
Not really. A heat treated, machine made stainless blade is still better than a smashed pipe.
im with you guys.Quality does matter here.
dwhp Sylkhr6 years ago
i`ve made one, but i painted it black and wrapped gold wire around the handle. Yay!!!!I made It today!!!!
Sylkhr (author)  dwhp6 years ago
Cool! I'll add your name to the list!
fragmaster45 years ago
No offense but that looks more like a crow bar :P
this is a piece of pipe that has been flattened not a sword but it looks very realistic :)
sites235 years ago
it still would not slash
sites236 years ago
could it slash or ateast cut something in half
You can probably stab someone like a real sword if you sharpen the tips.
IceTeaEdwin5 years ago
This is great! If you make a sheath with cardboard and line it up with a strip of metal you can unsheath it with that "shhiiiiing" metal sound. I'ma use this for my halloween costume, I was looking for good swords at stores but I want something that won't break. Thanks a lot!!! :D
ninja guy5 years ago you wunt to know hot to wrap the handle here is how to do it
Nice...Looks like a zanpaktou. Anyone who has seen bleach knows what im talking about
i see bleach everyday... under the sink i dont know what a zanpaktou is though
me and you have got similar avatars
Its from an anime. Its basically a sword, most of the time a katana All Soul Reapers possess a zanpakutō (斬魄刀, zanpakutō? literally "soul-cutting sword"), a sword that has a spirit created by their powers. By learning the name of the sword's spirit, Soul Reapers can unlock more powerful forms of their zanpakutō. The first form, known as shikai (始解, shikai? "initial release"), changes the sword's appearance to better facilitate its special abilities. The second form, known as bankai (卍解, bankai? "final release"), can only normally be achieved when a Soul Reaper trains with their zanpakutō for decades. Once achieved, the Soul Reaper can unlock their zanpakutō's full potential, increasing their own power several times over source:wikipedia
he was being sarcastic
I think the Bokken Instructable looks more like a Zanpakuto I made one for my Friend Kenny's Birthday (Kenpachi for short and, Yes it is a nickname) He loves it and is always using it.
lol they make the real version of ichigo's chain and all. it's in a shop near newport Oregon.
yobwoc5 years ago
about the pine sap on step 2... dont use the sword around a flame thrower (BBBOOOOOOOOO00SSHH) XD
WurdBendur5 years ago
I have a hammer exactly like that.
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