Wesley Scoggins
Indy Mogul
Wesley's Weekly HOW TO: Knight's Sword
After Erik did the Ninja Special, where he showed you how to make you're own Katana, many of you requested for a Medieval European-style sword, and now you're finally getting what you've long waited for, a cheap Medieval style sword that you can fight with and not accidentally cut off your friends head.
I started with two thick wooden dowels, a longer one for the grip, and a shorter one that will act as the Cross-Guard.
I started with the grip drilling a hole in it, and gluing a wooden dowel into it similar to my Prop Foil tutorial. The dowel is going to act as an internal support for the blade material.
Which is going to be (just like the Katana) some foam board. I just measured out about 2 inches wide, and cut it off using a straight edge and an x-acto knife.
I cut indentions into the top of the handle, so I could push the foam into the handle a little.
I then sealed the edges with wood glue, then compressed the edges together to give it a sharper look to it.
I got some Metal repair tape, you can find this at most hardware stores, and it's basically aluminum foil on a duct tape roll.
I then covered the blade, starting with the edges, the same as the Katana design.
I then reinforced the base of the blade with epoxy. After that dry, I spritzed the blade and the grip with chrome spraypaint, and drilled a hole through the handle in the same direction of the blade.
The shorter piece of wood I cut earlier, I drilled in two through the center. I used this flathead bit because as it cuts through it gives a curve to the ends of the wooden pieces, allowing it to hug closer to the central grip. You can just cut them in two and stick them against the handle with flat heads, but I like the curved edge more because it's tighter and a bit more structurally sound.
I drilled a hole of the same thickness into each segment of wood, and pushed a dowel of the same thickness as the holes through the handle.
I then reinforced those with more epoxy.
I painted the handle and cross-guard gold, then added a crown onto the end of the cross-guard using a styrofoam ball, same as how I formed the pommel in the Prop Foil.
I did the same on the other end of the cross-guard and made a pommel on the end.
Then painted them gold.
I then got the same cotton twine, and I wrapped the central part of the blade in it as decoration, then painted wood glue on it to make it hard so it won't unwind.
I then got some black acrylic paint and applied it on with a rough brush to give it an aged worn look. Darkening the details on the crowns and pommels, and darkening the twine to make it look like leather.
And there you go, the sword is completed. For a sheath you could make a pocket out of two pieces of cardboard, or create a sling sheath by adding a loop of duct tape onto a belt. You could also combine this sword with some modified samurai armor, and the gauntlet tutorial , to start making yourself look more like a real Knight, good luck!
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