Introduction: Wood Stick Sword (3 Hour Build)
With the recent winter storms, there has been a serious spike in the need for wood stick swords, for good reason. Nothing protects better, or looks cooler than a wood stick sword.
If you live in a town that doesn't have a Wood Stick Emporium or, if your local wood stick big box store is out of direly needed swords, have no fear! The Instructable is here!
Yes, I'm being tongue-in-cheek here. But in all seriousness, everyone needs their own wood stick sword. Think of all the cool stuff you could do with one: fight off your young, rabid cousins, look tight as you practice your martial arts, impress your family and friends as you slice and dice in the kitchen with might and gusto. Hurrah!
-1/2 box of wood sticks (Popsicle sticks)
-Glue (I prefer Tacky Glue)
-Metal clips (I have small ones)
-Rubber Bands (x5ish)
-Paint (I prefer cheap acrylic paint)
Step 1: Build Main Line
Complete steps 1 through 8 on the drawn instructions. You are making a three foot long center line which you will build from.
A word from experience- buy cheap, strong clips to hold your sticks in place as your glue dries. This will save you considerable time and many, many headaches!
Step 2: Reinforce Main Line
Complete steps 9-12 from the drawn instructions.
Again, use your clips!
Step 3: Repeat Reinforcement
Complete steps 13-18.
By now you are probably sensing a trend with working with wood sticks. Repetition is at the heart of this building process.
During this process, you may have to turn your clips sideways in order for them to hold your sticks together. This is one main reason why I use the metal clips over cheaper wooden hanger clips.
Step 4: Glue Horizontal Guard
Yay, no more work on the main line (for now)!
Complete steps 1-3 of part 2 of the drawn instructions.
Gluing on these horizontal sticks is tricky, as you will have to wait till they dry to move forward. I couldn't get my clips to hold here, so it was old fashion finger pressure for this step.
Step 5: Glue Cylindrical Hand Piece
Complete steps 4-5 of Part 2 of the drawn instructions.
This part is not complicated if you think through it before starting.
The whole goal here is to create a circular rod to hold. First, clamp four sticks together until they dry. You will glue these two stick combos onto the opposite sides of your handhold part of the sword.
To finish this step, you will glue four wood sticks to fill in the gaps, creating a nicely spherical rod for you to hold.
I decided to add another layer of sticks to make the rod larger but you don't have to.
Step 6: Reinforce Hand Guard
Complete steps 6-7 of part 2 of the drawn instructions.
Glue together 5-6 sticks (x8) and clamp until the glue is dry.
With ample glue, insert these pieces into the hand guard as shown.
Rubber bands are helpful in this situation as you can keep everything in place until the glue is fully dry.
Step 7: Flat Layer on Blade
Time to do Steps 1-3 of Part 3.
In this section, you are gluing wood sticks along the length of the blade to give it a flat, smooth look.
You'll notice I switch to "night photography", I apologize for the quality of the lighting in these photos. My headlamp is good for working, but not such for pictures.
With wood sticks, you will find that things are not 100% smooth, straight or even, especially when working on large projects like this one.
As long as you can get the wood pieces to glue where you need them too, the overall look will still be incredible. Indeed, each wood stick creation is uniquely its own, due to the nature of each wood stick used.
Step 8: Blade Edges
Complete steps 1-10 of part 3.
This step is a little tricky as you have to place your clips correctly, otherwise your glue has no hope of drying correctly.
But, bear in mind, if you are getting frustrated: this building material (wood sticks) is very forgiving. Your end project will look sweet, even if a few of your pieces glued wonky.
Step 9: Painting/Reinforcing Your Sword
Even if you don't plan on painting your sword, this step is still very important!
For wood stick projects, this last step is the most important.
With a wide paintbrush, "paint" glue over all of the project. This could get messy, so make sure you put down a towel or other material you don't mind getting glue on.
If you are using paint, make a 50/50 combo of your paint and the glue. Two birds with one stone! This will give your project a glossy finish and a smooth handhold. I chose to add a layer of Modge Podge to give it extra shine.
And just like that, you are done. Go off and fight your stormy battles!