Sword Construction

I already mentioned the different kinds of cardboard in a previous post, but I'll show examples in this image above.

The same type of techniques here, were used to build my Master Sword. This design is obviously a lot easier to build, so I just layered corrugated cardboard until I got the thickness I needed. If you want it stronger, cross your pieces from horizontal to vertical each time. I used a mix of double thickness, and single until I got the width I needed.

The dowel in the middle, runs all along the blade, and into the handle. You want to make sure it at least goes 1/3 into the handle, otherwise it'll be more likely to break at the guard, and you'll be stuck with nothing but a hilt in your hand... Dowels are not limited, you can use wood, fiberglass, cylinder types, piping, etc. I've even used a fairly straight branch before. This just allows you to swing your sword without it bending/breaking oddly by the force.

Cereal boxes cover my rough design at the top, and all along the blade. In the second image, you can see me start to add each part. If you don't want breaks in your line, buy those large poster boards at the dollar store. As long as it's thin, because this is where you'll be pinching the sides together to get a nice sharp edge. Your pattern should extend beyond the dowel inside, if you have cardboard pieces too, just make sure it's passed your outer edge.

Oh.. word of caution. I'm used to handling hot glue directly on my fingers... as you hold the edge together, be prepared for a bit of pain and juggling fingers quickly. It's not a pleasant feeling. I just get the best results doing it by hand.