How Ti Make A Wooden Case Template

How to build a sword out of forest, then make it look metallic and battle-worn. This sword was made for a Nazgul costume for a Lord of the Rings Halloween.

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My husband needed a big sword for his Ringwraith costume, so he created a template to make a sword that matches The Lord of the Rings pic prop. He used the Witch Rex's sword for his pattern. This sword design could be used to make a sword for any character or costume, so he's sharing his free printable pattern and how he made his iv-foot sword.

Our whole family dressed up as characters from The Lord of the Rings, so be certain to check out our costumes here. And the Nazgul gauntlets made of foam here. Plus, there's a video on how to make a unproblematic shield here.

Nazgul Sword Supplies

Wood Cuts

2×1/2-inch boards in pino or a soft wood
- 40-inch length for the bract
- 30-inch length for the crossguard
2-inch round dowel for the handle, a 14-inch length

Other Supplies and Tools

Aluminum foil record
Gum gun
Sand newspaper
Painter's tape
Blackness spray paint
Rub North Buff in pewter or argent
Steel wool
Black leather
Electric tape

How to Make a Woods Sword

Download the Sword Template

Print out the template and record the parts together. This is a big sword, so it takes several pages to get the full length. Cutting out each of the pattern pieces, then tape the blade template together by matching messages.

Print out the free sword template here

Cut Out the Sword

Cut the blade shape (ii inches x twoscore inches) along the lines drawn on the blade. I used a bandsaw to cut out the shape.

Shape the Blade of the Sword

Put blueish painters record with the edge down the centre of the blade. Then sand the wood to knock off the square edge of the blade till it is half way forth edge. Flip the blade over and do the same on the other side. I institute the bluish tape helped forestall sanding down other side so I could get a ridge downwards the middle of the blade. Don't sand between section "G" and "F".

Add Aluminum Record to the Sword Blade

Use aluminum foil tape and apply information technology over the border of the blade. This doesn't have to be perfect but simply cover all the parts of the woods. This makes the wood look metallic. The bract with aluminum foil tape was very shiny and didn't wait right with my Nazgul costume. Then I decided to us a wire brush to scratch upwards the blade. This added a lot of cool texture to the blade.

Add Age and Battle-wear to the Sword

The Blade still was too bright so I sprayed it with a light glaze of black spray paint and wiped it down with steel wool. This wiped off the top layers of paint but kept some of the darker areas in the scratches.

Make the Sword Crossguard

Cutting the woods for the crossguard into two pieces that are 2 inches past ix.5 inches. Also cut two additional filler pieces that are 3.25 inches by 2 inches.

Trace the template for the crossguard onto one of the longer piece of wood. So place the other crossguard piece downward on table and gum the two filler pieces on the outside edges. In that location should be enough infinite for the blade to fit snuggly between the filler pieces (Don't glue blade withal). And then mucilage the second cantankerous guard piece (with template drawn on it) on elevation the other parts. Then clamp all of the parts together and let information technology dry overnight.

Cut and sand Crossguard

Once the gum is dry, cut forth lines drawn on the Crossguard. Over again, I used a bandsaw to cut. One time the shape is cut, sand the edges and confront of woods until it is shine.

Add Designs to the Crossguard

Using a glue gun, apply a bead around the edge of cantankerous guard to create a design. Do this on both sides of the cross guard. Then spray paint a base of operations glaze of black spray paint over both sides.

Brand the Sword Handle

Cut the 2-inch round dowel to 14 inches long. Using a Dremel, sand paper, or a lathe, carve the dowel to be the shape of the template. Then sand to finish edges. And so use hot glue around section "E and A" of the grip and pommel to create a decorative blueprint. Then apply a layer of black spray pigment as a base coat.

Assembling the parts

Cutting a notch in the top of the handle so that information technology slips over the crossguard. Next slip the blade through the hole in the crossguard and use woods glue to adhere. Then slide the notch of the handle over the crossguard and use wood glue to connect these parts. Clench everything and let it dry out overnight.

Make the Sword Design Look Metallic

Now the part I really love. Apply Rub and Buff in pewter or silver to the tiptop edges of the hot glue gun bead on the crossguard and handle. The best way to make Rub and Buff work is to utilize it with your finger so rub over it with a fabric to make the metal shine. That's where the name comes from, first you "rub" it on, then y'all "vitrify" it to a shine.

Cover the Sword Handle with Leather

Using newspaper, measure out effectually section "B" & "D" and cut a newspaper templet for both areas to wrap leather around the grip. Use the template y'all just made to trace blackness leather and cut it out. Then wrap electrical tape around section "B" and "D" then the sticky side is out. This will assist your leather to stick to the grip expanse. Then using some thread sew together the edges of the leather to the grip.

This photo shows a shut-up of the finished sword hilt so you tin meet all iii parts assembled together and finished.

Click here to run across the full Nagul or Ringwraith costume. Y'all can read how to brand the cloak here and how to make the gauntlets out of foam here. Plus, don't forget to bank check out all of our other Lord of the Rings costumes here.