This instructable will show you how to take a $12 Prince of Persia plastic prop (say that three times fast! Ha!) sword and turn it into something you might actually want to accessorize your pirate costume with.
I had most of this stuff in my crafty closet. You may have to make some purchases. This whole project cost me about $20, but if you have to buy everything, it may look more like a $50-$75 sword/dagger/cutlass, in which case, you might do better to buy a replica anyhow.
The inspiration for this came from TribalDancer and her turorial on modding a pirate gun. Check out her 'ible here: http://www.instructables.com/id/Steampunk-Pirate-Gun-Mod/ . If you want to know what kind of awesome costume either of these accessories could adorn, you can check out a story about my pirate costume on my website, www.ericayoung.com. I'm pretty new around here, but I just finished my first Instructable here so check it out, too: A steampunk necktie corset dress for all (okay, maybe several) occasions!
Step 1: Gather Supplies
Or, if you're not like me, you will need:
• coarse & fine sandpaper (100 & 220)
• 1" trim brush - the wispier, the better
• detail paint brush
• small file - a metal nail file works fine
• nail clippers
• strong tape/glue
• masking tape
• some weights - heavy machine screws & fishing weights worked for me.
• pewter & Grecian gold Rub n' Buff paint
• orange, beige, & brick red acrylic paint
• black, brown, & red spray paint
• gold spray paint for fishing weights
• matte acrylic sealer
• terry cloth towel
• spray adhesive
• fabric glue - I used Aleene's
• scrap of red velvet*
• sewing scissors
• needle and thread
• plastic pirate cutlass
• rubber or latex gloves (**optional)
• beer (also optional, but delicious)
*The red velvet was an afterthought. I will take you through the steps needed to make your scabbard look wooden, and then I will show you how to cover it in velvet or other fabric.
**If you elect not to use latex gloves, your hands will look like this at a minimum. I, personally, do not like to work in gloves because I think it's harder to feel what I'm doing. If you work in a service profession--especially food service--you may want to think twice about this because these paints will hang out on your skin and under your fingernails for a couple of days.