Instructables
Picture of Wooden Prop Sword
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Irregardless of the type of sword that you build, it may be part of your costume and needs to go where you go. If this is so then you will need a safe alternative.
This sword is made from pine slats , it is not sharp but still looks real from a distance.

You will need a Drum/Belt sander. (quick shaping, hand shaping will take a relatively long time.)
Pine Slats. (local HD sells for $12 for 25)
Spray Paint, Primer, silver, gold
Electrical tape, I used red

The total build not counting the drying time was less than an hour.
 
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Step 2: Make the hilt

Picture of Make the hilt
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The hilt is from the same type of slats as the blade.

Cut and glue several pieces together, Clamp the pieces for the best results.

The hilt is three sections of slat material thick with a space in the middle for the blade slat to go through.

Normally I would use a wood glue but time was short.

The hilt is then roughly shaped on the sander.

Step 3: Make the pommel

Picture of Make the pommel
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The hand grip and pommel are also a laminated slat. I glued and clamped 3 pieces together then shaped on the sander.

Step 4: Prime and Paint


Due to imperfections in the wood it is a good idea to fill the holes with a wood filler. Again time was short and I had some drywall filler which worked.

Begin with a rough sand then progress down to a fine grit sanding paper. the smoother the wood the better the finish

I chose to primer the wood with a white primer to show imperfections. These were filled then sanded.

I primed the blade again with a gray primer then used a top coat of metallic silver.Hang to dry.

The bare hilt was sanded smooth then primed and a top coat of metallic gold was applied (not shown).

The pommel was also painted gold.
If you want to make your blade look more metallic you can cover it in metallic plumbers tape. Pros about is are that is fairly cheap and you can sand, grind, or brush the tape just like ordinary metal.
Somehow I'm only just finding this. That's a great idea for the tang. I might have to impement that.
schlypdog2 years ago
I sure hope you do make a copy of the Zabuza sword I would love to see what you come up with. To me he is the coolest character in all of Anime. Anyway thanks for this design I am using these plans to put the finishing touches on my William Wallace Costume. One question, did you sharpen the the blade?
timmycutts2 years ago
That sword looks so cool. It's just a shame you can't use it for anything besides a costume prop... I personally find pine to be a nuisance for making swords. Sure it's easier to work with, but it lacks the durability to be worth the effort of making the sword in the first place (what's the point of making a sword that you can't use). I made mine from a piece of meranti, took longer, since it's hardwood, but it's been used quite a bit and hasn't splintered or broken yet (and probably won't).
Amazingly done, and a nice technique that I intend to copy for my own blades. Any suggestions on how one might make a sheath, or as to how a thinner blade would work?
I have not tried to make a sheath but a simple belt loop worked for me . A thinner blade tends to be brittle in single ply. I was going to remake in 1/4 inch plywood for strength and a thiner blade
Hrm. Intriguing. Though, I'll likely stick to this design and just adapt my plans a bit. Is the blade stable enough that one could theoretically Dremel in a few runes?
curvy772 years ago
very nice. got any more designs?
Random_Canadian (author)  curvy772 years ago
I have been playing around with the construction of Zabuza's sword. If I get it right I will post it later.
curvy772 years ago
carve out a small section in the middle of the pommel and glue or soder in a stone. ( any kind of smooth rounded stone should work) make it look even better.
Kaiven3 years ago
This Instructable is the most useful wooden sword one I have seen, thanks for sharing! I didn't even know I could buy pine slats; they would've helped on a lot of projects. Time to make some Christmas presents ;)
Random_Canadian (author)  Kaiven3 years ago
Thanks for the comments. I am starting to have an unusual love for the pine slats. I am using them for everything now...
Back again. I've made three swords so far but have found the hardest part is beveling the sword. The only tools I have or various saws, a jigsaw, circular saw, and belt sander. Is there a simple way to use one of these and bevel the blades? I already tried the jigsaw, and it's a pain in the neck to get anywhere near straight.
Carleyy3 years ago
This is awesome!
Random_Canadian (author)  Carleyy3 years ago
Thanks.

Hope you are enjoying SF I miss it tremendously...
Hypernone3 years ago
You remind me of Adame Savage from the show Myth Busters :)

This looks cool.
colorex3 years ago
Battousai!
Random_Canadian (author)  colorex3 years ago
not quite but I try...