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...
Step 3: Adding the Handle Detail
Step 4: The Blade
I used a hand held electric sander to thin out the blade and bevel the edge
I used a coping saw for the tip.
I used my dremel to cut the base of the blade into a tab to fit into the matching notch in the cross guard.
I used my dremel and a rasp and files to do the detail work.
Step 5: Attaching
Step 6: Painting
After it dried I watered down some black acrylic paint and did a couple coats where I brushed it into the detail, wiped it off, let it dry, repeat, until it looked like I wanted it to.
Step 7: Leather Grip
I sprayed the back of the leather with a spray adhesive wrapped it around the handle and put a bunch of rubber bands around it.
Step 8: Finish
If you want you can add more details. You could weather the blade, or add blood splatter. You can add more features to the grip. Some versions I've seen have a wire wrap design overtop of the leather. You can also stitch the seam in the grip up if you want. I might do that to make it more durable but it's not required.