How to Make a Wooden Sword

There’s a reason wooden swords never go out of style. They’re safe, they’re nostalgic, and best of all, they’re fun to make. Whether you’re a parent looking to build a toy for your child, a cosplay enthusiast needing a prop, or just someone who enjoys weekend woodworking, making a wooden sword is a satisfying project that blends creativity and craftsmanship.

Why Build a Wooden Sword?

It might sound simple at first—cut a plank, round the edges, and boom, you have a sword. But there’s a charm in shaping wood into something that feels like it belongs in a storybook. For me, the first wooden sword I made wasn’t for a project; it was for a costume I needed at the last minute. I had a dull handsaw, some leftover oak, and about four hours. The result? Not perfect, but memorable.

Wooden swords make great gifts for kids, and they offer a creative outlet for anyone interested in medieval history, fantasy lore, or just hands-on learning. Plus, no batteries needed.

What You’ll Need (Tools & Materials)

Tools:

Jigsaw or coping saw
Sandpaper (80 to 220 grit)
Clamps
Wood rasp or file
Drill (for crossguard/dowel holes)
Pencil, square, and measuring tape

Materials:

1×3 hardwood board (poplar or oak is ideal)
Wood glue
Wooden dowel (for reinforcement)
Wood stain or acrylic paint
Clear finish (polyurethane or polycrylic)
Leather cord or cloth strip (for handle)

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Step-by-Step: Crafting Your Wooden Sword

1. Draw Your Design

Sketch your sword on cardboard first. I like keeping it to around 30 inches total, with a 24-inch blade and a 6-inch handle. Trace the shape onto your wood with a pencil.

2. Cut Out the Shape

Clamp your board down and use a jigsaw to follow your outline. If you only have a coping saw, that works too, just takes more time. Remember to go slow around the curves.

3. Bevel the Edges

Take your rasp and file the edges down into a soft bevel. You don’t want sharpness—just enough shape to give the illusion of a blade.

4. Attach the Crossguard

Cut a 6-inch piece from the same board or a scrap. Drill a centered hole halfway through the thickness and slide it over the handle with glue. You can reinforce it with a dowel or a screw if you want it solid.

5. Sand Everything Smooth

Start rough with 80-grit and work up to 220. I usually sand the handle a bit more to give it a nice grip.

6. Paint or Stain

This is where it gets fun. Stain it for a realistic medieval look or go wild with acrylics. Once it dries, apply a clear protective finish. I prefer Minwax Polycrylic for its fast dry time.

7. Wrap the Handle

Wrap the handle in leather cord, old shoelaces, or even strips of t-shirt. This gives it grip and flair.

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Optional Customizations

Runes or Symbols: Woodburning tools make this easy.
Fantasy Styling: Add metallic paint, jewels, or even foam accents.
Weathered Look: Dry brush black paint over silver for an aged metal feel.

For the Kids: Mini Sword Build

If you’re doing this with young kids (under 8), scale everything down:

Blade: 18”
Handle: 4”
Use softwood like pine
Round every corner aggressively
Seal with kid-safe, non-toxic finish

Let them decorate it with stickers, paint, or markers. Just be sure they don’t use it to hit their siblings.

Common Issues & Fixes

Problem: Crossguard won’t stay in place.
Solution: Add a dowel through the handle or reinforce with a screw and glue.

Problem: The wood split during cutting.
Solution: Use hardwood without knots and cut slowly. Don’t force the blade.

Problem: Paint bled under stencil.
Solution: Use repositionable adhesive or painter’s tape and dab lightly.

Safety First

Don’t let kids use power tools without supervision.
Always round edges and sand splinters.
For full-contact use (like mock battles), add foam padding.

Wooden swords are great toys, but they can still sting. Always talk about safety before handing one over.

Display Ideas

Finished swords look great on a wall rack, especially if you’ve customized them. Use a basic wall hook or screw two pegs into a board for a rustic display. You can also paint a shield backboard and mount it as wall art.

History Corner: The Wooden Sword Legacy

Wooden swords go back thousands of years. Roman gladiators trained with wooden versions before entering the arena. Samurai practiced with bokken, and medieval squires learned with wood before ever touching steel.