Woodworking, How To Make A Wooden Sword

By March 20, 2017Builds, Projects
The Finished Wooden Sword

Today I’m going to be showing you how I make a wooden sword. I’ve included a build video, article, and a link to my Instructables how to build a wooden sword article. Let me know if you have any questions, and thanks for checking this out!

The Build Video:

A couple pictures of the finished sword:

The Finished Wooden Sword

The Finished Wooden Sword

The Finished Wooden Sword

Free Wooden Sword Plans

Here are the wooden sword plans I drew after I made this project. They represent what I built off the top of my head pretty well.

And in-depth build article:

I’ve posted an in-depth, how to make a wooden sword build article on Instructables if you’re interested in learning more about this project. I went into way more detail than I do here. There’s also a set of plans for this wooden toy sword that you can find there as well.

The Build Article:

Now for the fun stuff, let’s talk about how to make a wooden sword. This is a quick run down of all of the steps that I took in this woodworking project. From start to finish, this is how I made a toy sword out of wood.

Cross cut all your work pieces.

Cross cut all your work pieces.

I cross cut everything on the table saw with a table saw sled. Of course, you could use a miter saw, or even a hand saw. Heck, a jig saw works too.

Rip all of your work pieces.

Rip all of your work pieces.

Then I ripped all of my pieces for the wooden sword on the table saw. Ripping means you cut the workpiece long ways. It’s the opposite of a cross cut.

Rip your handle and blade down to 3".

Rip your handle and blade down to 3″.

Then I ripped the handle and grip down to 3″. This is a little bigger than the blade at the widest part, but it helps me make all of my cuts further down the line.

Resaw the handle and blade to 1/2".

Resaw the handle and blade to 1/2″.

Then I resawed the blade and grip to slightly over 1/2″. This let’s me plane it down to 1/2″, and make it perfectly smooth.

Plane your handle and blade smooth.

Plane your handle and blade smooth.

Then I planed the board to 1/2″ and smooth.

Layout your wooden sword.

Layout your wooden sword.

This is pretty simple. I just made this up as I went, but here’s a link to the wooden sword plans I drew afterwards.

Cut the shoulders for the sword handle.

Cut the shoulders for the sword handle.

Then I cut out the shoulders on the table saw sled with a stop block.

Cut out the handle on the bandsaw.

Cut out the handle on the bandsaw.

And cut out the handle on the bandsaw.

Cut out the blade shape on the band saw.

Cut out the blade shape on the band saw.

I rough cut out the blade.

Sand to the line with the disc sander.

Sand to the line with the disc sander.

And sanded to the line on the disc sander.

Chamfer the edges you want chamfered.

Chamfer the edges you want chamfered.

I chamfered the edges on the router table.

Mark out your joinery.

Mark out your joinery.

And the laid out, and marked all of my mortises with a knife.

Chisel out the waste.

Chisel out the waste.

I chiseled out the waste with a very sharp 1/2″ chisel.

Chisel out the pommel's mortise as well.

Chisel out the pommel’s mortise as well.

Then I chiseled out the mortise on the pommel, as well.

Test fit your joinery.

Test fit your joinery.

After test fitting everything, it was ready for some finishing touches.

Chamfer the edges of the pommel and cross guard.

Chamfer the edges of the pommel and cross guard.

I used a sharp chisel to chamfer all of the edges on the cross guard and pommel.

Glue up the cross guard.

Glue up the cross guard.

I applied glue, and tapped the cross guard home.

Glue up the pommel.

Glue up the pommel.

And then did the same thing with the pommel.

And I'm done! This is how I make a wooden sword.

And I’m done! This is how I make a wooden sword.

And I was done! So this right here is how you make a wooden sword. Thanks for checking this out! If you didn’t know, I post these videos to YouTube, if you’re interested you should check it out!

Thanks Again,

— Adam

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