All it takes for bad props to triumph is for good project dads to do nothing. Or something like that. So when a coworker of mine told me about the cardboard sword she was going to make for her boyfriend’s cosplay costume, I could not just stand by and let it happen.
First of all, this is not just any sword. Her boyfriend is dressing up as Link from the Legend of Zelda! I totally get that this project is not super exciting for a lot of you who may be reading this, including my wife, but I had never done anything like it before so I thought it would be fun to see if I could do it.
Apparently there are ComicCon rules that prohibit actual metal swords so this one would need to be made out of wood. The first task was to design the hilt. I used some clipart images from the web, my scroll saw, and Dremel (love my Dremel) to fashion these “wings”.
We needed a half sphere which turned out to be pretty tricky. She found me a wooden ball that was the right size so I just needed to cut it in half. Here’s a tip: Don’t try to use your miter saw. I ended up just using a hand saw, even though it took a while to get through.
The whole sword will be put together with one long bolt that will hold it all together so I drilled a hole through the ball.
The center piece was pretty easy with my scroll saw and a scrap of 3/4″ wood. I just cut it to shape, used my Dremel for a little decorative lines, then drilled the hole through for the bolt.
I drilled a pilot hole slightly smaller than the bolt into the wood of the blade, then screwed it in nice and tight as far as I needed. The idea here is I will cut the head off the bolt and do the same thing into the handle.
The blade was a 1×6 board with the end narrowed to a point. It’s hard to see but I even ran it through my table saw on end with the saw blade at an angle to give the sword blade a beveled edge. Not too sharp, of course.
The handle is a wooden dowel with a door knob on the end that looks like a large gem.
Once the sword was built, I handed it over to my coworker to work her decorative magic. A little paint and some colored tape and it turned out amazing.
Here they are off for their big weekend. Link and the blue fairy. Not a bad job for my first sword attempt. Believe it or not I have already made another one. Keep and eye out for that when I post about His Grace the Warrior King.
Here are some of the tools and supplies I used in this project. If you are interested in one, click to take a look. You get a fun product, I get a fun commission. Thanks!