I decided to make the sword in three parts. Handle, Cross Guard, and Blade. Then I used a threaded metal rod to to make sure the connection between the three pieces was secure. It might have been easier to do one piece that started as the handle and turned into the blade and then attach the cross guard to it, but I already started before I thought of that and rather than lose momentum dwelling on how I could have done it I just kept on pressing on.
The supplies I used were:
-Thin pieces of wood (I got mine from a pallet)
-A threaded metal rod
The tools I used were:
-Rasp and files
Step 1: Design
Once I had the design traced onto the wood I cut it out with a coping saw.
Step 2: Shaping the Handle
After I had it shaped the way I wanted I drilled a hole into the end of the handle and through the cross guard. I also used my rotary Dremel to cut a slot into one side of the cross guard for the blade to fit into and a hole on the other side for the handle to fit into.
I got a little ahead of myself drawing the detail on but that's for the next step...