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Make a Knight's Templar Sword Part 2

In this part of the tutorial we glue together the parts of the sword.

 

 

Cut out the parts

Now cut out those six parts.

The six parts

 

Will

Will's Tip on Cutting Foam board: Don't try to cut all the way through it in one swipe. Use a really sharp blade and make three passes. the first pass just cuts the top layer of paper. Second pass cuts the foam and the third pass cuts through the bottom layer of foam.

 

Assemble the Pieces together

 

Glue the blades together

Glue the two blade pieces together, one right on top of the other.

 

Glue the first two handle parts together

Next glue the first two handle pieces together. This a full handle on the bottom and a handle with the cutout on top.

 

Clean glue out of the slot

Clean any excess glue out of that cut out section.

 

GLue on a second slotted piece

Glue on the second handle piece that has the cut out section. And again clean any excess glue.

 

Test insert the blade into the handle

Now test fit the blade into that cut out section. Don't glue it before testing it. This way you can trim it to size if you need to. Once you have a good fit then you can glue it in. Use plenty of glue and be sure to put glue on the edges too.

 

Finish gluing the handle

Finish the assembly by gluing on the final handle piece. The sword is built. Now we just have to clean it up before we paint it.

 

Trim the edges

Because we have a stack of pieces there will be inconsistencies in the stack. You can see there are ragged and uneven edges. Trim the edges all the way around the sword to make it as even and smooth as possible.

Sand the edges

Then sand all the edges for smoothness.

Next Lets Make the Blood Groove in the sword

 

RESOURCES AND MORE

Knights Templar Shield

Measuring 24 inches high by 17.5 inches wide, this wonderful testament to medieval warefare is a great conversation piece. Bound with brass and bearing a symbolic red cross, this kite shield comes ready to be hung in any armory.Shields come in a variety of shapes and sizes, and were used throughout the centuries for defense. A shield of this type would have been used by only the wealthiest of knights, due to its brass bindings and ornate decoration.