I worked up this project so that my princesses could also slay dragons, it works just as well for Knights, Princes, and Spartan Warriors.
The Sword is a simple design that uses a Home Depot Yard stick as the core.
Step 1: Materials
The blade of the sword is made from a home depot yard stick (paint department $.98), I added a layer of chrome paint for flourish. The handle is wrapped with hockey tape for a better grip and look. The Cross-guard and Pommel were 3D printed using PLA.
Begin by printing the Cross-guard and Pommel. I used a low resolution setting with 3 shells and 20% infill, this gave me a solid part that can take some abuse from the kids (me). The parts I designed are specific to the yard stick that I purchased, you may need to scale the parts a bit to get a nice fit.
I designed the parts for a tight press fit, this way the handle stays together without adhesive.
Step 2: Forging the Blade
The blade must be forged in the white hot volcanic fires of HooMeeDe-pot by the dwarves of Krylon...
All kidding aside, The yardstick was sliced in half using a chop saw, i cut the blades to 18" this seems to be right for smaller children. Also the shorter length slows the tip speed (hurts less). I then shaped the tips into a more blade like design and blunted the tips for safety.
A quick coat of silver paint finished the blade off. You could also use bronze or copper paint for your spartan warriors.
Step 3: Assembling the Handle
The plastic printed parts are designed to be pressed into place, using an exacto knife I beveled the back edges of the blade slightly to help them start into the Cross-guard and Pommel. Be careful using the razor blade my efforts earned me two stitches, and mild disapproval from my wife.
If the blade seems loose, a bit of two part epoxy would be a fine addition.
Step 4: Wrapping the Handle
The handle was wrapped using hockey tape.
- Start by attaching the tape to one end of the handle and unrolling it 12-18".
- Hold the sword in the air with the tape roll hanging below, spin the roll until the tape twists into a thick string.
- Then wrap the twisted part of the tape around the handle with 1/4"spaces in between.
- When you reach the other end of the handle you should run out of twisted tape.
- Cover the twists with a single layer of tape to finish the look.
Step 5: Arm Yourselves
Arm your favorite Knights or Maidens and send them into battle. And remind them not to actually slay the dragon (dog)