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How to Easily Make a Wooden Sword

A wooden sword is an inexpensive substitute for the real thing. Paint it with metallic paint and wrap the handle with black tape to make it look realistic for a theater prop or Halloween costume. Leave it plain and use it hard to practice sword-fighting techniques. Be careful, though, since a sharp wooden sword is heavy enough and pointed enough to cause real injury. Choose hardwood such as hickory, oak or ash if you plan to hit or stab the sword against anything, since softwood can break and splinter.

Things You'll Need

1/4-inch by 2-inch by 60-inch hardwood
Coping saw
1/4-inch drill
Epoxy
Knife
Sandpaper

Instructions

- 1
  Outline a pointed shape on the end of a 35-inch by 2-inch by 1/4-inch piece of wood with a pencil to create the sword's tip. For a small child, make the sword a comfortable length, so you may want it shorter than 35 inches. Saw out the tip with a coping saw or jigsaw.
- 2
  Saw a 1/4-inch by 5-inch rectangle out of both sides of the other end of the wood to create the shape of a centered 1 1/2-inch wide handle that's 5 inches long.
- 3
  Saw a piece of hardwood 4 inches by 2 inches by 1/4-inch thick. Cut a slot in the center that's 1/4 inch by 1 1/2 inch. To make the slot, start by drilling a 1/4-inch hole, then insert a coping saw and cut out the rectangle. This makes the hilt.
- 4
  Slide the handle of the sword into the slot until the hilt rests against the back of the blade. Glue it in place with epoxy.
- 5
  Cut four pieces of wood 1 1/2 inches by 5 inches by 1/4-inch thick. Glue two to each side of the handle with epoxy, also spreading glue on them where they touch the hilt.
- 6
  Carve the corners of the handle round with a knife after the glue is dry. Sand it with sandpaper to remove any roughness.

Wooden Toys