Introduction: Max the Ninjato
Out of all the swords I've made, this is my personal favorite. I make a lot of foam weapons for various purposes, which you can find instructions for here.
This sword is made with a 1/4" fiberglass core, a craft foam blade painted with acrylics and mod podge, and a craft foam handle and guard.
UPDATE: I added a few (real, not sharpie) gears to the mini-screen side of the blade.