Hey everybody Propchap here with my newest instuctable the Pirate Sword!
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Step 1: Template.
I made a template of the blade on paper. here are the measurements I used: width:1 1/4 in, length:30 1/2 in.
Then I took the last 7 inches and narrowed down the middle 5 inches and drew a groove that go's in a 1/4 inch.
Then I curved the end to make look like the tip of a real sword.
For the hand guard I took my hand and another piece of paper (a smaller piece) and wrapped it around my hand then cut a little longer. Then I rounded the ends to make it like a real hand guard.
Step 2: The Blade.
Trace the blade template onto plywood about 1 1/2 inch thick. Cut this out on a scroll saw or a band saw (the band saw works best for the strait parts and the scroll saw works best for the round parts).
Step 3: The Hand Guard.
Trace the hand guard template onto cardboard and cut it out. Then trace the end of the sword onto both ends and cut that out.
Step 4: Gluing It Together.
Put the hand guard on the blade and hot glue it there. It should look like the pictures.
Step 5: Strengthening the Hand Guard.
I took some steel wire and bent it so it fit in the side of the guard. Then I hot glued it in place. I did the same on the other side.
Step 6: The Paint Job.
I sprayed the whole thing with gray primer spray paint and let it dry. Then I sprayed the blade and hilt with silver. Next I sprayed the hand guard with black.
Step 7: The Handle Wrapping.
I wrapped the handle in brown/orange cloth, gluing it as I went. Then I cut out two skinny long strips of tan cloth and made an X pattern on the handle with it.
Step 8: Finish!
Now you have your own pirate sword! If you have any questions leave a comment below and if you like this instuctable please vote it for the wood contest.
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