How to Make a Durable Cardboard Sword

Materials You Will Need:

• large sheets of cardboard
• aluminium foil, paint, or markers
• clear packaging tape
• a few short wooden skewers or dowels
• small rolls of clear tape
• scissors
• a pencil 

Introduction:

     In general, cardboard swords are floppy, flimsy, and easy to bend. Once bent, they will just lean over to one side and stay there until the bent part gets torn off. And trust me, that is not fun, especially if you are in the middle of a gladiator match with your violence-loving sister.

    I've made quite a few cardboard swords, yet my method may not be the best. The swords still break eventually, but at least they will not need as muck repair if one just traced the form of a sword on cardboard and cut it out. (Tried that, did that, and it failed.) 

    Okay! If you made it this far, applause for you. Now let's jump into it!

Step 1: Getting a Backbone

    This is critical for the durability of your sword. I usually used a few sticks made out of three bamboo sicks each, but that broke easily. The best thing you can use is a firm piece of wood. Also, it will be the length of your sword, handle included. Remember, though, it can't be too wide or thick. This is because you will be wedging it between two pieces of cardboard.

    The best thing I have ever used was a flat piece of wood about three feet long, 3/4 in. wide, 1/2 cm thick, and very flexible, though not too much so that it flops over like a wet noodle. The fact is, you need it to be slightly flexible so that it can absorb some shock. (Remember: this is for play, not to duel against a bear!)

Step 2: Getting the Shape of your Sword

    You would need two pieces of cardboard large enough to make the shape of the sword twice. (One per cardboard.) Draw the shape of your weapon directly on the cardboard, or on a piece of paper, whatever suits you best. I am used to be using cardboard left from boxes that were used to house stuff like cereal, furniture, etc. The best kind is about one layer thick, as two layers would make it slightly spongy and harder to work with.

    IMPORTANT: Please, please remember to make a mirror image on the cardboard, like one side is the mirror image of the other. If you don't, the two sides would not match when you put them both together in the end, the colourful side in, and one side would end up becoming a brightly coloured cereal box advertisement.

    At the end of this step, you should have a backbone and two mirrored pieces of cardboard the size of the backbone. Note: when drawing the sword, do not draw the hilt. That will be added later.

Step 3: Putting the Sides Together

    Just saying, there are many ways to do this, depending on how you plan to decorate your sword. One thing is persistent, though. First choose one side of your sword and tape the backbone to it, IN THE CENTRE. This is critical if you want a double-edged sword, which is what I make. Then bend the blade of your sword down the middle, right where the backbone is.

If You Are Painting your Sword:

    Paint it now. You will tape the cardboard together later for protection and to keep it together. Paint it until the cardboard is no longer visible, and let dry before proceeding.

If You Are Covering the Sword with Aluminium Foil:

    Don't do anything. Just continue.

    Okay. So now you would want to attach both ends together using small amounts of plastic tape you would find at the dollar store. First, take the bent side and attach it first to the unbent side with tape. You HAVE to keep it tight. If it is loose, the sword will fall apart. First, you would take one end of the tape and stick it well on one side, then pull slightly (not too much) and stick it on the other side. Do this every two inches. Then bend the side that should be sticking up and tape it on the other side. The sword must not be loose; it must feel tight. Wrap the handle with a bit of tape to keep it together.

Note: One would think that we should use glue. The reason this is probably not the best procedure is that the backbone tends to break. Then, if you used clear plastic tape like I used, you can just cut a slit in the side and insert a splint. Also, they break all the time. I just want to shorten the amount of times I actually have to repair them.

Step 4: If You Wanted to Use Aluminium Foil

    If you wanted to use aluminium foil for a metallic look, now cut out pieces that will fit your sword (avoid piecing things together like a quilt if you can) and tape them lightly to the cardboard sword. When the blade meets the handle, that is where you stop.

Step 5: Apply the Hilt

    Cut out a hilt, mirror image like the blade. There are many ways to built a hilt, and I am probably going to make a post on that alone. It is complicated. But make one of your choice, and if you want it to be 3D, then make it like a box, by sticking both sides of the hilt together and covering the sides with a cardboard strip.

Step 6: Make the Grip

    Cut out a strip of  cardboard and colour it brown, or take a strap that is brown. (It doesn't necessarily have to be brown, though.) Then wrap it around the handle until it is all covered.  You can even make pommel if you want.

Step 7: Protect the Sword

    Cover the entire sword with a layer of clear packaging tape to keep it from being torn or scratched if you used paint. It would look less nice, but this is for durability too. If you made this for a costume, you may not have to bother with this step.

Conclusion:

    Well, there you have it! That is how I made five swords and five daggers. (Cardboard, of course.) Enjoy amazing your friends, but once they overcame their amazement at your brilliance, they would probably ask to hold it, but then they will have revenge on you. (Jes kiddin'. But they just might pursue you with a cardboard sword.)

 

Notes:

• The dowels could be replaced, as mentioned, by a large stick. 
• Sometimes cardboard bends when you cut it with scissors. Use a knife if you do not want to risk it.