Making a real sword takes years of practice and dedication. The few remaining swordmakers in the world do not give away their secrets so easily and, even the training swords, made of wood and of high quality, such as the bokken (solid wood training sword for aikido) and the shinai (training sword in bamboo for kendo) require patience and skill to successfully complete them. Either way, anyone with a little time and a few tools can build a toy sword to duel with friends or have adventures with their son or daughter. Read the steps to learn how to make a toy sword yourself.
Steps
Part 1 of 3: Wooden Toy Sword
Step 1. Draw a sword on the paper
More specifically, draw the outline of a sword. Use a ruler to make it reasonably straight and then use all your creativity regarding the design. It doesn't have to be perfect. This will be the first draft of your sword.
To make a longsword using this method, you will need the longest paper. Consider using a butcher paper size, or buy some large drawing sheets from stationery
Step 2. Cut and copy the stencil
Carefully cut out the sword stencil and then lay it out on the wood you plan to use, which should be a fairly thin (no more than 2.5cm) panel of the wood of your choice. Copy the stencil onto the wood and then copy the handle (hilt and guard) of the stencil twice more.
The hilt will be thicker than the blade, so you'll need to cut three pieces of wood and then glue them together
Step 3. Cut the wood
Using a jigsaw, cut the three pieces of wood you shaped - two pieces for the hilt and one for the whole sword. The cuts will probably be a little rough; that's okay. Make sure you cut with a little more space instead of a little less - the extra width can be cut, but if a piece is missing it is more difficult to put it back.
Step 4. Mix some epoxy and glue the pieces together
The next step is to take a strong wood epoxy glue and mix it to activate it. Mix it on a piece of paper for easier cleaning. When the mixture is active, distribute it evenly on the side of each piece of the hilt and glue them firmly to the center piece, one on each side.
- When the pieces are glued, wait for the glue to dry completely, at least 10 minutes.
- Line up the pieces as evenly as possible, but don't worry if they aren't perfect yet.
Step 5. Hone your sword
Start on the hilt side. Use fine sandpaper to smooth the rough edges and smooth all three parts. You can use a rotary to speed up the process if you want. When the hilt is smooth, use sandpaper to smooth the sides of the blade, making it "sharp".
Step 6. Check the hilt and do the finishing touches
Check that the hilt of your sword is not too big to hold comfortably; if it is, sand it both sides to make it thinner. Place the sword on a graduated surface and check that both sides of the guard are straight, and that the blade is straight enough on both sides. Sand away the uneven parts until the sword looks symmetrical enough.
Step 7. Add decorations
Start by painting your sword. At the base level, you should paint it by spraying some spray to give it a coat of gray undercoat. As soon as the base has dried, you can add some metallic color to give the sparkle or colors like blue or red to make a "lightsaber." When the paint is dry, add something that makes it easier to set. Duct tape is fine, as is fabric wrapped and held together with glue. You can also wrap strands of leather around the handle and tie it. Finally, use whatever decorative element you want, add some finishing touches.
- If you cover the hilt of the sword while you paint with the spray and undercoat, you can leave it with the natural look of wood. Alternatively, think about giving the gold spray on the hilt and silver on the blade.
- Try gluing rhinestones to decorate the center of the guard and the pommel (base of the hilt).
- If you like, when you're done spraying, you can use a small brush and acrylic paint to add detail.
Part 2 of 3: Stuffed Sword
Step 1. Start with a length of PVC pipe
The tube should be hard but not fixed when shaken. A tube with a diameter of 2.5 or 3.5 cm is fine. Using the saw, cut the tube to the length of the handle combined with the blade of the sword. Think about whether you want the sword to be usable with two or with one hand.
Step 2. Wrap with foam
Cut a piece of closed cell foam (which comes in a cylindrical shape, with a hole for the tube in the center) for the length of the sword plus a few cm. Slide the tube over the PVC tube.
Step 3. Add a guard
If you want, add a guard by sliding a four-way tube, mounting it on the end of the hilt of your main piece of PVC. Cut two short pieces of the PVC pipe, both of the same length. Slip a piece on each open side of the work to create a guard. When you are happy with the width and position, use plastic concrete to secure each piece in place.
Step 4. Add more foam
Optionally, to make the sword safer to use, add small pieces of closed cell foam to each end of the guard and to the base of the hilt. This has the added benefit of creating a kind of "apple".
Step 5. Peel off the masking tape
Start by wrapping the handle in duct tape. Cut it when you reach the base of the guard and lay it out so that it is smooth. Then, wrap the duct tape so that it gives thickness around the base of each piece of foam, helping it secure it to the tube. Add pieces of tape tightly around the foam to secure them even better. Finally, wrap the entire foam blade with duct tape from bottom to top.
The last few inches of foam should extend past the tip of the PVC for safety, feel free to wrap this "soft tip" and, closing the hole at the top
Step 6. Wrap it up and enjoy
Tape every other piece of foam you added completely with masking tape. The duct tape gives the metal a shiny look and protects the foam from the elements. When your weapon is finished you can use it to stage fun battles with your friends wielding stuffed swords. The swords are soft enough to prevent serious injuries, and now let's get started!
Part 3 of 3: “Katana” with a Metal Ruler
Step 1. Get the materials
You will need a metal yardstick or tape measure, a thick stick with the diameter equal to the width of the ruler, raw steel wool, sandpaper, primer and fabric or duct tape to wrap around the grip, as well as the cement or metal fixer adhesive epoxy resin for metals. You will use a saw to cut and split the dowel; A vise is also recommended, but is not strictly necessary.
Step 2. Rub the ruler
Use enough steel wool to scrub the ruler and as much as possible to clean and roughen the surface. If there are marks painted on the ruler, the wool may also eliminate them, do not hesitate to make them disappear if this is the case. When you're done, wipe the ruler with a clean, dry cloth.
Step 3. Cut the stick
Measure a stick length that fits well as a handle and cut that piece off the end of the stick. Measure and mark along one end at the center point, and then carefully saw the stick into two even parts, two half-cylindrical halves, using the saw guide to hold the stick in place.
Step 4. Attach the stick handle
Lightly level the insides of each half of the stick with fine sandpaper. Following the instructions for the epoxy or concrete fixer, evenly glue each smooth part from the base of the ruler and let it dry completely.
If you have a vise, squeeze the pieces firmly (without damaging the soft wood) and let it dry in that position for more grip
Step 5. Sand and prepare
When the handle of the stick is secure, sand the excess glue from the joints and then weigh it in your hand. If the grip feels awkward to you, try sanding the sides a little more, alternating equally on both sides, until the grip becomes more oblong and can be held more easily. When you are satisfied, cover the handle with painter's tape and apply a coat of primer spray first on one side of the blade, then on the other. Apply another layer to completely cover any marks on the ruler. Let both layers dry completely.
Step 6. Roll up the handle
Remove the painter's tape from the handle and sand it with very fine sandpaper to remove any splinters, then wrap it with a plaster, duct tape or leather string to make the handle softer. Your new katana is finished! The flexibility of the ruler blade ensures that it wobbles instead of breaking or bending when you hit things.
This sword may have a square tip and a flat blade but it can still do a lot of harm. Be very careful when playing with it. Hit only inanimate objects, such as training dummies
Warnings
- Even a toy sword can do damage if used irresponsibly. Supervise children with toy swords, and use restraint and discretion when using them yourself. An assault with a wooden sword is still an assault.
- As always, treat tools with respect and wear safety gear as you build these swords.
