This was a fun project and it is about making a Katana using just wood.
Step 1: Get Materials
2 Wood planks: 7x30 inches and 7x7 inches
Wood coating (polish)
Bandsaw (A jigsaw will work as well)
Katana Handle wrap
Step 2: The Handle
Making the handle is actually pretty easy. First you have to take 2 wooden rectangle piece. The wooden blocks should be as long as your forearm in length. ( 10 x 1 1/2) . Get a chisel and cut a rectangular shape for the bottom part of the wooden blade to slide in. Chiseling at the wood and frequently going at it with a file will make it smoother and you will have a valley deep enough.
Step 3: The Guard for the Handle
Making the guard is also pretty easy. All you need to do is print out a free template and cut it out on to wood. I cut the wood piece with a jigsaw. It did not take long but all you need to do is smooth out the circular part with a file. You should end up with something that kind of looks like the picture above. If you don't rush, it will look better than mine.
Step 4: The Blade
All you need to make the blade is to draw and cut out. That is what I did. It took me a while to draw the exact curve of a Katana. With some patience and time you should be able to get the right shape. Make the to draw the dowel that slides in to the handle.
Cutting it out with the jigsaw was actually easier than I thought. All you need is the right shape of the blade on paper, tape it on the wood, and you should have no problems.
With the bandsaw, I cut it in half in order to get the right thinness I had some trouble doing it with a jigsaw so I switched to the bandsaw. If you look at a katana you will notice that it has a shape like a wedge and with the sander you should be able to get the right shape for the blade by sanding it at an angle.
Step 5: Assembling
Now that you are done with the hard part all you have to do now is assemble it, but first you are going to need to polish all the individual parts. once you polish all the parts and let it dry, you will now have to connect all the pieces with wood glue. After everything is dry, take the handle wrap and start wrapping the handle. I used a Youtube video on how to wrap a handle and it took some practice but after a while you should be able to get it done.
That is it on how to make a wooden katana!