I used this tutorial to make the swords for my Zoro cosplay. I actually found this on DA, I didn't realize there was a post on cos.com.
My only changes to the tutorial were that I used Poplar wood instead of Pine and just used the excess wood scraps from cutting out the blades to make the tsubas, rather than buying MDF board.
Sagely Advice To Base One's Life On:
-If you give a man some fire; he'll be warm until it goes out, but if you set a man on fire; he'll be warm for the rest of his life.