Introduction: Halo Energy Sword

Picture of Halo Energy Sword

in this instructable i will be showing you how to make an energy sword from the halo series.

.hot wire cutter
.carving knife
.wet and dry emery paper (230grit)
.acrylic paints
.25mm Styrofoam

Step 1: Drawing the Templates

Picture of Drawing the Templates

open a cad drawing program that allows you to draw over an image (I used the Corel suite). Collect a flat image of the energy sword and copy and paste it into the program. Use the tools within the program to draw over the different sections of the sword (2 blades and a handle). Group these items together and scale the size to suit your height.  You then need to print these off so that you can trace them onto the Styrofoam. Once printed use masking tape to stick the stencils to the foam and use a pencil to trace the stencil through leaving an indent to follow. Remove the stencils once traced.

Step 2: Cutting Out the Parts

Picture of Cutting Out the Parts

now that you have traced the design through you can use a hot wire cutter to cut out the shape. You can also use a craft knife to cut it out if you do not own a hot wire cutter. Do not worry if the shape is uneven as you can sand it at a later stage. Once cut check the cut outs in comparison to the stencils to check that they roughly match. If there are any areas that are completely off you can cut some foam off to make it correct or if need be re-cut the part.

Step 3: Sanding the Parts

now that you have the cut outs you can now sand them to smooth out any imperfections on the pieces. I used 230 grit wet and dry emery paper to smooth of edges and to even out the faces of the foam. This is done as it is easier to carve a flat surface than a bumpy one. Keep sanding until you are happy with the finish.

Step 4: Carving the Parts

Picture of Carving the Parts

now you need to draw some rough lines to help you carve the edges to keep accuracy. These do not need to be the same as mine as I was not sure of the exact angle for the blades and the handle. Once you have used the carving knife to shape the pieces you can use the emery paper to smooth off the cut edges. Do this until you are happy with the finish.

Step 5: Construction Method

Picture of Construction Method

now that you have all of the pieces carved you can use wooden sticks (I got them from ice lollies) to attach the blades to the handle. To do this you need to choose the position that looks correct on your model and make holes just smaller than the sticks so that there is some friction to ensure a good hold. Now take out the sticks and you are ready for paint.

Step 6: Painting the Pieces

Picture of Painting the Pieces

mix up the acrylic paints to the correct colours and paint the foam pieces. You can do several layers if need be. Leave the pieces to dry fully before moving on. Once the coats have dried you can use a dry brushing technique if you want to add a rough used look to the prop (I did not do this as this was a quick project).

Step 7: Final Construction

Picture of Final Construction

now you are ready for construction. You need to use a hot glue gun to glue the wooden sticks into the pieces. You do this by adding some glue to the top of the hole on the piece and pushing the stick down and that will give you a solid hold. Additional glue can be used but you should be careful not to ruin the finish and look of the prop.BE CAREFUL THAT YOUR GLUE GUN IS NOT TOO HOT AS IT CAN MELT THE STYROFOAM.

Step 8: Enjoy Your New Toy

Picture of Enjoy Your New Toy

now that you have constructed your fine weapon you can show it off to your friends and play around with it as you wish. Enjoy your new toy and wall decoration.


Mister_M (author)2017-08-16

I've played Halo 1, partially 2, 3, hated 4. When I heard 343 was making Halo 4 I lost my mind, I was like "SERIOUSLY?! WHY?! Bungie ended it at 3 for a reason!! C'mon man!"

mbrucato1 (author)2016-06-22

Nice, now you should mold it and make a more sturdy plastic casting.

Look at some stuff on Smooth-On:

Pee-Ka-BooG (author)2016-04-30

I only have Halo Wars. :(

awesomecreations (author)2013-06-06

Cool! I love Halo, but I have only got the first one.

Beokapi (author)awesomecreations2016-03-07

I guess it's too late to warn you about getting 4 and 5.

I like it too. I am kinda in the same boat as u. I only have Halo 1 and 2. Oldies but goodies!

nemesisprime (author)Plo Koon2014-12-10

i have halo 3, and 2, but i want combat evolved (halo 1) halo 4, halo wars, halo reach and odsts

Plo Koon (author)nemesisprime2014-12-13

Currently, I actually have all that you mentioned, except for Halo Wars (its been a while since I left that comment). I haven't really played Halo 4 or ODST yet, because me and my bros are big fans of Halo: Reach. I'll get around to them though.

nemesisprime (author)Plo Koon2014-12-13

well, i think my brothers getting me Halo: combat evolved for christmas ... :) which do you prefer? bungie or 343?

Plo Koon (author)nemesisprime2014-12-14

I actually have never played Halo: Combat Evolved Anniversary, but I did beat the original. If you want to see the game that started the Halo franchise, buy the original Halo: Combat Evolved. However, if you are a big graphics fan, choose CEA (it also has a Firefight mission).

nemesisprime (author)Plo Koon2014-12-15

well, halo 3 is really cool. but my arbiter isn't the best assistant. but we are stuck on the storm, any one got tips?

Plo Koon (author)nemesisprime2014-12-15

I haven't really played the Halo 3 campaign yet (except for part of a level at a friend's house). Just 1, 2, and Reach. However, I and my brother are going to try to play through Halo 3 over Christmas break. I'll get back to you after that.

Which is your favorite weapon (you can't say Rocket Launcher) out of all the Halos you've played? It's kind of hard for me because my preferred weapon differs by map and opponent, but my favorite is probably the Halo: Reach Sniper Rifle, followed closely by the same game's Assault Rifle.

nemesisprime (author)Plo Koon2014-12-19

i'm an assault rifle guy. but if i'm in halo 2: grenades and an energy sword.

but if i ever got halo mcc, id use the infected one

Plo Koon (author)nemesisprime2015-01-08

You must have some mad grenade skills to fight like that.

Also, I found this on YouTube. It might help with your Halo 3 problem:

nemesisprime (author)Plo Koon2015-01-08

well, i'm almost done with combat evolved, just got to escape the autumn. also, thx

Doesn't matter. Killed me some Covenant. ;) Haha yeah any Halo is awesome!

thank you. who doesn't love a bit of halo :)

I know right...

(Gonna kill me some Covenant)...

chockenbury (author)2016-03-06

I'm working on a way to make this in wood instead of styrofoam, that way I can also burn the alien text into the blade(using wood burning of course)

Blockbreaker0501 (author)2016-01-11

Amazingly simple!

SebastianMichaelis (author)2015-11-01

*finally can complete my covenent weapon set* YASSSS

rquezada2 (author)2015-10-14

making one in red, for this is what I wanted

Na101 (author)2015-10-11

This is so cool, thanks!!!

NamedJohnny made it! (author)2014-10-20

Following all your steps, here is mine! Thanks for the idea

looks amazing :) thank you for using my guide

angryrobot17 (author)2014-07-19

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Starboy001 (author)2014-06-28

Looks easy.

angryrobot17 (author)2014-06-19

where to get the foam cheap, other than internet?

sorry for taking a while to answer but i currently have not found anywhere other than online to get Styrofoam.

TheStuUurgE (author)2014-03-26

This is the best done plasma sword that I've seen on instructables

thank you i'm glad you liked it :)

Avocodo (author)2014-05-16

What type of foam did u use, what is it called

Avocodo (author)Avocodo2014-05-16

im making this an the dead line is soon

blackbeltsean97 (author)Avocodo2014-05-16

it is Styrofoam i use and i hope it goes well for you :)

This is Awesome!

azolina4 (author)2014-02-13


dcloud1 (author)2014-02-06


SwaggerFul Swellow (author)2013-06-19

I have a LEGO version that is custom made from Brick arms that is just like that! Nice!

cool :) thanks for the comment

omex (author)2013-06-07

Cool sword!! Where do you get the styrofoam from in uk? I cant seem to find it in shops anywhere.

blackbeltsean97 (author)omex2013-06-07

i get mine from a company called hindleys. heres alink to the styrofoam page. thank you for the nice comment :)

redfoxtrystman (author)2013-06-06

I'm going to make one out of wood. I'll post a able soon

nice im looking forward to seeing it :)

simplebotics (author)2013-06-06

Dang it, I just made one a week ago out of cardboard. Today, I just made a sticky detonator that actually shoots. I'll try this!

cool and have fun :)

picosoaaron (author)2013-06-06

Should be pointier

i agree but the material is hard to sand to a point :(

theslingshotkid (author)2013-06-06

will the styrofoam break if you wack someone with it?

I would not recommend wacking someone with it. It is a fairly strong material though and could take a hit or two. thank you for your comment.

About This Instructable




Bio: I'm Sean. Im currently studying for a BA in Artist Designer: Maker. My interests are Anime, Comic Culture and prop making.
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