Highlander: Kurgan Sword

About: Just a huge movie geek, looking to get a little bit of the movies in my life.

"I have something to say! It's better to burn out than to fade away!" - The Kurgan (Highlander)

When the YouTube series Film Riot announced their new "Monday Challenge" (scene remake), I got excited. I wanted to do a shot for shot remake of the final fight from one of my favorite movies... Highlander. I already had a replica of Connors katana (a birthday present to myself), but I needed the sword of one of the greatest villains ever put onto a screen; The Kurgan. You can view the final video here. Lets begin!

(Note: this will not be an exact replica, I just made it to look as close to the movies as possible for the video.)

Step 1: The Sword

I started with the basic sword. I found a leftover wooden stake from a haunted house I did on Halloween (Video Here). I took it in and measured it to make sure it was the right size... and it was PERFECT! From what I hear the entire sword is 4ft long and thats what the wooden stake is! Using a reference photo I drew the shape of the tip onto the wood and cut it with a saw.

Step 2: The Handle

I took a wooden dowel and traced it on the bottom foot of the stake. I then cut out the the traced area so that it was the same diameter of the dowel. Then I cut the dowel down the middle and glues it on with hot glue; and if thats not enough I also DUCT TAPED THE CRAP OUT OF IT! Tape it! The real handle of the sword has black leather as a grip, for that take some small rubber electrical tape and bring it all up and to the end. Do this Twice to give it an "x" pattern. I then cut off the extra wood thats on the bottom of the handle. For the little ball on the bottom, I took the end of a curtain rod and spray painted it silver glue that to the end and you're done with the handle.

Step 3: Cross Guard

For the cross guard I printed out a screenshot and traced it onto a piece of cardboard. I made two cutouts and added reinforcement in between the two pieces. I glued it between the handle and the blade. Using light cardboard, like a cereal box, I filled the space between the halves.

Step 4: The Mini Blade

Take apart a Clothespin. Cut both halves of the wood so they have a point. Put silver duct tape on them. Done.

Step 5: Metal

Its hard to explain this part. So this is the video I found that made me do it this way. Do the same to the Hilt and you now have a very metal looking sword!

Step 6: Adding the Mini Blades

I Just cut a spot in the top of the Cross Guard and glued it in.

Step 7: "There Can Be Only One"

Done! Not bad for a one day build! I will upload the video when its ready! I hope you like this instructable! If you have any suggestions on how I could make it better, comment below. If you want to see more replicas, follow me. More Builds to Come!

Step 8: Some Photos From the Shoot

These are some pictures we took while we were making the video.

Final Video



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    7 Discussions


    Question 11 months ago on Step 1

    How long is the blade and the handle and the crossguard of the Kurgan sword


    4 years ago

    Have you gotten a real kurgan since you made this ?


    4 years ago

    the piece you called "the hilt" is actually the the cross guard, or cross piece, the hilt is the handle

    2 replies