So about a week ago i was bored and after reading a few posts about the difficulties of making very large prop swords. I decided it was time to give it a shot.
Now my Materials i had all of them just laying around my place.
*A large piece of cedar plank.(used for shelves)
*A Long Steel Pipe.
*And a Piece of flat steel (about an inch wide, and how ever thick you want it.
Tools were a hand held circular saw, jig saw, belt sander, hand planer and drill.
Okay. so first pick what ever big anime sword i want.
I go with the Zabuza sword ala naruto.
First you take your plank of wood and measure out about a foot wide section. cut that off and that will become the basis of your blade.
Now i know it may not be perfect scaling, but i went with 1 foot wide at the tip, where it has the swoop, and about 8 inches wide at the base where the hilt attatches.
it looked roughly like this
after some rough shaping with some hand saws and a rough cut jig saw.
Now unless your really REALLY good with your saws i would NOT go for final dimensions on the first cuts. leave about a half inch all around. you can always get rid of extra later. but if you cut to much off, then you wasted that whole piece of wood.
Now the plane, i used one with a 1 inch blade. i used it to literally sharpen the edge. the damn thing can almost cut. it takes alot of patience and a sharp plane, but just remember to only plane away half and then do the other (same as sharpening a knife).
The handle, I had a piece of large very heavy steel pipe welded onto the middle of the flat steel. now to attatch this to the sword, i drilled three holes in the flat bar.
This is very
in the wood, you line up the holes, mark them and drill pilot holes.
number 1 rule, of pilot holes. use a smaller dril bit then the screw/bolt you want to use.This lets the wood not split when you drive a huge bolt thru it, but still gives it PLENTY of wood to get the threads into.
Number 2, make sure it goes straight down. anything off and your compromising the strength of the wood.
now with that done. i used heavy duty 4 inch long wood bolts to attatch
now then if you have it i recommend sealing the gap and applying lock tight or gorilla glue to the screws for the extra umph.
Now i still have to cut out the hole in the top and the half moon in the middle, i will edit in the completed sword with details of how i will be painting it tomorrow. This is a work in progress. but even tho this will be heavier than a foam sword. the quality WILL show thru with this.
Here is the semi completed sword.