Make a realistic looking sword that's great fun to play with, won't hurt anyone, looks brilliant and is made in a way that is not entirely dissimilar to the way a real sword is made. There seems to be a lot of steps, but in reality there are only one or two crucial ones, the rest are obvious once you know how.
You will need:
You will need:
- A couple of old toothbrushes (buy some new ones if you don't have any spare)
- Some thick baking foil
- A wire coat hanger
- A very short piece of garden hose pipe or something similar
- About 3 metres (3 yards) of electrical home lighting ring main cable (optional)
- A cupboard door knob
- A hot melt glue gun (with at least 3 long sticks of hot melt glue)
- Some strong cardboard
- You will benefit from being able to use an oven (on a very low heat)
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Signing UpStep 1: Bend a coat hanger into shape
You are going to be casting your sword in hot melt glue with a foil skin. But so that it will be springy like a real blade, it needs a stiff core. I used a bent wire coat hanger for my core, and that seemed to work fine. If you have other similar wire then you could use that instead, but make sure that there are no sharp ends near the tip of the blade, because they might poke through the plastic outer skin and hurt someone by accident.
Pull down the bottom bar of the coat hanger and push the sides in. Straighten out the hanger as much as possible, taking care to make sure that it is not twisted or bent. This is not as easy as it sounds, because the coat hanger wire is quite springy. We need this property for later to make the blade have a spring to it, but at this stage it makes it hard to work with.
Bend the coat hanger hook round so that it is a narrow loop but centred and in a straight line with the rest of the hanger. This will\mean bending it back slightly so that the centre of the loop is centred on the axis of the straightened out hanger.
Pull down the bottom bar of the coat hanger and push the sides in. Straighten out the hanger as much as possible, taking care to make sure that it is not twisted or bent. This is not as easy as it sounds, because the coat hanger wire is quite springy. We need this property for later to make the blade have a spring to it, but at this stage it makes it hard to work with.
Bend the coat hanger hook round so that it is a narrow loop but centred and in a straight line with the rest of the hanger. This will\mean bending it back slightly so that the centre of the loop is centred on the axis of the straightened out hanger.
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Bravo.