A Sword for a Knight

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Project by sethwells posted 10-21-2014 12:05 PM 2580 views 2 times favorited 6 comments Add to Favorites Watch

My 6-year-old son is going to be a knight for Halloween this year. A week ago we went to Renaissance Festival where he saw a wooden sword that he wanted to buy for part of his costume. It was very simple and looked mass produced, but they still wanted about $20 for it. So I told him that we would not buy a sword, but I would make him one and it would be much cooler than that one. Of course, I made this promise while having never made a sword before.

The next day I had to get to work on it because (he would not stop asking me about it) Halloween was quickly approaching. We looked online at some pics of swords and he told me which kind he liked the most. Then I gathered some scrap red oak pieces and started figuring it out.

A couple of days later he was wielding the sword you see!

I really enjoyed making it and it wasn’t all that hard. It’s made of 4 pieces – the blade, the hand guard, the grip and the ball. I don’t have a lathe, so I purchased the ball from Michael’s.

The blade and the grip are connected by a dowel with the hand guard sandwiched between. On the top of the guard I chiseled out a space for the blade to seat in and on the bottom I used a forstner bit to create the hole for the grip. The blade and the grip actually make contact inside of the hand guard.

The ball is also attached to the grip using a dowel.

I created the bevel on the blade by making 4 angled cuts on the table saw – the last of which was relatively sketchy because at that point there was only one small edge on the table and one small edge on the fence.

Again, I don’t have a lathe, so for the grip I cut the shape as best as I could with the bandsaw and then just used by belt sander to smooth it into a conical shape.

The sword has no finish on it yet. He thinks he might want to paint it. ~gasp~

6 comments so far

View ChrisK's profile


2034 posts in 3470 days

#1 posted 10-21-2014 12:23 PM

Great job. My son wants a Ninja sword for Halloween. Do not know if there will time for one. Again, nice work.

-- Chris K

View jumbojack's profile


1688 posts in 3013 days

#2 posted 10-21-2014 03:13 PM

Excalibur quakes in the presence of this fine blade. Nice job. Your little guy looks pleased.

-- Made in America, with American made tools....Shopsmith

View mcoyfrog's profile


4757 posts in 3983 days

#3 posted 10-21-2014 06:38 PM

Awesome blade, they are so fun to make thats for sure

-- Wood and Glass they kick (well you know) Have a great day - Dug

View BTimmons's profile


2303 posts in 2874 days

#4 posted 10-21-2014 08:08 PM

Well done. Looks like a happy customer.

-- Brian Timmons -

View robscastle's profile


6132 posts in 2593 days

#5 posted 10-21-2014 08:34 PM

Always time to make stuff for kids, no matter how busy the schedule !

And a noble effort in the process.

Wassail !!

-- Regards Rob

View TopamaxSurvivor's profile


18571 posts in 4064 days

#6 posted 10-22-2014 01:04 AM

Great job Dad!

-- Bob in WW ~ "some old things are lovely, warm still with life ... of the forgotten men who made them." - D.H. Lawrence

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