TMNT Leonardo's Katana

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No one kicks more butt than the Teenage Mutant Ninja Turtles. Although there are four of them, everyone has a favorite. If his suiting up as the TMNT this Halloween or convention season, don't forget your character's signature weapon. Create Leonardo's Katana with the help of this tutorial by Wholesale Halloween Costumes.

Step 1: Materials You'll Need

  • 1/2” x 8” tube pipe insulation (found at most hardware stores)
  • 10” x 20” matte board
  • Spray adhesive
  • Craft knife
  • Scissors
  • Ruler
  • Tan, silver, dark grey duct tape

Step 2: Create the Blade

Measure out one section of matte board 20” x 1.5” and two sections 20” x 1.25” each. Cut them out. Draw a curve on the end of each piece, and cut. This will make the end of the final blade look curved.

Layer the 3 pieces of matte board together, so that the widest piece is in the middle. The pieces should be flush on 3 sides. Use the spray adhesive to attach the pieces together to create one long blade. The blade may still be a little flimsy until the next step.

Apply a long strip of silver duct tape along the length of the blade, wrapping half of the tape on each side of the blade.

Step 3: Reinforce the Blade

Finish wrapping the blade in duct tape. Use long pieces of tape to minimize any visible seams. Use the craft knife to trim edges around the curved end of the blade. The tape will help make the blade less flimsy.

Cut the insulation foam open about 4”, splitting it lengthwise. Sandwich the flat end of the blade between the foam. Hold the foam and blade tightly closed together and wrap the handle with tan duct tape.

Step 4: Create & Attach the Guard

To create the guard, measure a 3” x 4” piece of matte board, as shown. Round the corners of the guard. Measure a 1.5” x .25” section in the middle of the guard, large enough for the blade to fit through.

Cut out the guard and the middle section. Cut a slit from the middle opening through one side of the guard.

Use the cut opening to slide the guard over the blade.

Hold the guard closed and wrap in dark grey duct tape. The guard should fit snuggly and will be attached to the handle more securely in a future step.

Step 5: Create the Handle

Cut a piece of grey duct tape (approximately 12” long), and fold in half lengthwise. The tape should stick to itself. Cut and fold 3 more pieces of grey duct tape.

Tape one end of a piece of folded duct tape, to the underside of the guard.

Wrap the folded tape around the handle at an angle, and tape at the base, as shown.

Rotate the handle, attach the end of the second piece of folded duct tape to the underside of the guard and wrap around the handle, as shown.

Repeat steps 15-16 applying the tape in the opposite direction. When complete the tape will create a woven look on the handle.

Step 6: Finish the Handle

Cover the bottom of the handle with a piece of silver duct tape. Wrap the top and base of the handle with a 1” strip of silver duct tape.

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