Legendary Wooden Sword

I chose to craft a wooden sword because of how it feels to wield one, as well as how it strikes the imagination. Often I don't see enough people using things they've gained from their own success, but rather the success of others (think of all the things we use in our daily lives). This sword, once crafted to perfection, unlocks that feeling of success, that you made it. I remember the excitement of first building it; now, I am giving you the chance to feel that same awe. All that is to say, 'trust me, the work is worth it!'. So, in the end, no matter how it turns out (unless you fail to follow the instructions provided); to whatever extent you allow yourself to go, you will have crafted, a complete, wooden sword.

1. Douglas Fir (1" x 5.5" x 31.5")
2. Pencil
3. Framing Square
4. 4' Level
5. Tape Measure
6. Table Saw
7. Band Saw
8. Orbital Sander
9. Draw Knife
10. Rasp
11. Chisel
12. Sandpaper (150, 80 grit)

1. Using the tape measure, pencil, and a straight edge mark out the center-line along the length of the 1" x 6" on both sides.
2. Measure and mark 26" (length-wise) from the end of the 1" x 6" and square the center-line for the cross-guard (draw a line, perpendicular to the length of the 1" x 6"). Do this on both sides.
3. Measure 1" from either side of the center line, above the cross-guard, and at the end of the blade on both sides. Connect these marks using a pencil and a straight edge. The overall width of the blade should be 2".
4. Measure 3/4" from either side of the center-line below the cross-guard, and at the end of the hilt on both sides. Connect these marks using a pencil and a straight edge. The overall width of the hilt should be 1.5".
5. To mark out the cross-guard measure 1/2" from either side of your perpendicular line (as drawn in Step 2 of Step 1) at the center-line and then mark 1" from either side at each end of the cross-guard. Connect these marks using a pencil and a straight edge.
6. To achieve the flared effect for the swords cross-guard, sketch a curve from the marks that you made in Step 5 of Step 1.
7. Measure 5" from the end of the blade and mark either side. Draw a line from each mark to the center-line at the end of your blade.

1. Using the table saw, cut along the lines you made in Step 3 of Step 1.
2. Using the table saw, cut along the lines you made in Step 4 of Step 1.
3. Using the band saw, finish the cuts you made with the tables saw.
4. Using the band saw, cut along the lines you made in Step 6 of Step 1.

1. On the edge of the sword, draw 2 lines 1/4" from the face of the sword along the length of the blade, and the hilt. Do this on both sides.
2. Clamp the sword to a sturdy surface like a table/workbench, and using a drawknife, shave away wood on the blade at a slanting angle from the center-line to the line you drew on the edge in Step 1 of Step 3.
3. Apply the process you did in Step 2 of Step 3 to the hilt.
4. Using a rasp and chisel, shape the cross-guard and soften any remaining edges.

1. Using your Orbital Sander (with 80 grit sanding disks), sand all surfaces until smooth. Use your sander to finish shaping your cross-guard.
2. Finally, hand sand the entire sword (with 150 grit sandpaper) until smooth.

Congratulations! Your Sword Is Now Complete.

During this rich and enjoyable process of creating an exciting sword, I learned that patience and caution (when used appropriately) always turn out for the better, making this experience unforgettable. Regardless of where you are as you read this, I hope you can take something away from this, and if you enjoyed this as much as I did, I wish you good fortunes with your newly made sword. From this project I learned (as I now think everyone should learn at some point), that hard work is not just toiling away at something, but it is rather the result of persevering until either your motivation ends or your work is complete.