I will walk you through the untraditional way of makeing a 100% real katana
The Quality depends upon you!
I AM NOT RESPONSIBLE FOR ANY MISUSE OR INJURY CAUSED AND OR INFLUENCED BY THIS INSTRUCTABLE.
making swords in some countries is illegal without an arms license, and you can get fined and possibly charged for wielding a weapon if someone sees you in public with this
Step 1: Tools and Materials
Two vice grips, you can probably get by with one pair and a friend.
Pliers with cutting edge
One handed sledge hammer
Power drill with a drill bit(s) as wide as the nails and dowel rod you have.
Vice with anvil on the back
Anvil if you don't have a vice with one.
Large sledge hammer if you don't have the two above.
Power grinder or belt grinder
You can get great steel deals at www.admiralsteel.com
20 gauge sheet metal for Tsuba(Guard) ,habaki (blade collar) ,and for the pommel witch I have not figured out how to make.
1/4 inch by 1 inch wood for handle
Steel pictured in thumbnail 5.
Flat and wide shoe laces black are best but you can use any color.