Aluminum Prop Sword

If you need a prop sword that is light, yet durable, for the screen, stage, or cosplay, here is a fairly simple and inexpensive option.

Research the type of sword that suits your needs. Whether it's an already established design, or something you come up with based on inspiration, or history, know what you are about to build. It's not to say that you won't take it in different directions as you go, but it's good to have a baseline plan.

Put what's in your brain down on paper. That way you don't risk losing the "vision." Sido, it gives you a chance to make adjustments that you never thought of as it sat in your brain.

*design shown is different than finished product

Use a marker to draw the design onto the metal. Using proper protective gear, grind the shape of your sword with a bench or handheld grinder. Then use a radial, belt, or hand sander to smooth the rough edges. Be very careful, and very deliberate in getting rid of burrs and rough spots.

Take the freshly sanded flat bar and use it to trace the shape of the hilt onto the poplar wood piece. Cut the wood using a band saw. Make two matching pieces for both sides of the hilt. Glue them to the flat bar, or drill at least two holes and place metal or wood dowels into the holes for pins. Finally, and the wood to desired shape, thickness, contour, etc., and stain the wood a desired color.

Use assorted leather pieces to create a wrap around the hilt. Stich the leather together. Then, use leather strap on the edges to hide the edges and to give a nice finished look. This is all up to you. There's no one right way.

Use or make ornamental pieces that pop out from the rest of the design. Round pieces usually look good in this setting. Glue or otherwise fasten the pieces where you feel they work the best. Also, beads and feathers can give a cool, ancient look.

Use a stain or paint wash and go over the whole sword including the blade if desired for a weathered look. Brush it on lightly and use a rag to gently wipe off excess stain or paint. Finish it off with a generous spray of clear coat in a flat offering. This will seal it all in.