This is a instructable on how to make a Swordin FIVE STEPS. If you have a forge you can heat treat yours but I don't so I did't right that step.
Jig saw with metal blade or any thing you can cut medal with.
Step 1: Cutting the Metal
Cut the Metal 38 inches long. Then round the tip of the long metal piece.
Then cut a piece of metal 8 inches long.
Step 2: Holes in the 8 Inch Piece
Then drill holes in the middle of the 8 inch piece of metal. After you drill you should be able to slide the 38 inch piece of metal through the holes you drilled.
Step 3: Welding
Weld the 38 inch piece of medal to the 8 inch piece of metal. There should be 8 inches of metal sticking out the other side of the 8 inch piece (for the hilt of the sword).
Step 4: The Hilt
Cut a 2 pieces of wood 8 x 1 1/4 inches. For the thickness just find the right thickness that fits your hand.
Then screw the wooden pieces to the metal one wood piece on each side of the hilt.
Then rap some rope around the hilt and tie the end.
Spray paint the sword so it doesn't rust.
Step 5: Done!
You are DONE! Now go and make another one for your brother so you can fight him.
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