This build is Sakura’s The Sword Card from the anime Card Captor Sakura.
My first step was to model the sword in google sketchup. I did not spend too much time worrying about the curves and details. I just needed the general shape and size.
Next, I got myself some 1/4″ (or was it 3/8″? I can not remember) poplar wood and traced the blade onto it. I believe this was 2″ by 36″.
After my initial cut with the scrollsaw (this was my only power tool that could do straight cuts at the time) it was a bit jagged. Today I would have used my table saw to cut it straight the first time.
So to straighten out the edges I used my router and router table. I adjusted the fences so that 1/16″ of the material would be trimmed off.
Perfectly straight now.
The next step was to use my router and give the blade an edge. I used my 45 degree angle bit for this part. The fence helped to insure that I didn’t mess up and dig into the blade.
Next, I used my router to take out the middle of the dowel rod I was going to use for the handle. I believe I used a 3/4″ dowel rod.
Next a test fit of the blade slide into the dowel/hilt.
A nice fit, I went ahead and used wood glue to hold it together. Next, I used some 1/2″ pine board to cut out the feathers for the hilt and hand guard.
Next I used my dremel to shape and sand the feathers. I used a routing bit to round the edges and then the sanding bit to smooth it some.
I then used a beveled routing bit to round out the inside part to connect to the dowel and then glued on.
For the hilt tip, I glued two wood buttons together.
Next, I cut out the sword tip using 1/2″ pine wood.
I do not have a picture of it, but for the above piece I had to cut off the 2 smaller parts that would attach to the sword. The reason being I needed to remove material to slide the sword blade in. This can be seen in the next picture.
The gems were cast with Tap Plastics clear cast resin and I used molds that you can buy at your local hobby store.
I then attached the hand guard and the hilt’s jewel holder. The hilt jewel holder was made from paper clay. I got the perfect circle by using the bottom of a paper cup (as you can see in the above resin picture that I filled with red resin).
Everything is now glued together. Time to apply primer.
Next, I masked off everything but the pieces that would be painted gold. First a layer of black.
Now to apply the gold paint.
Next, paint the blade silver.
I then hand painted the hilt with pink acrylic paint. And glued on the gems with E-6000. And now the sword is complete!