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Will
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Make a Pirate Cutlass with a secret treasure chest - Part 2

In Part 1 we traced out the various parts of the sword. Now we cut them out and put them together.

 

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.

 

The cut out pieces

Cut out those five pieces.

 

Note the dotted lines

Now we are going to cut the lid for the treasure chest. Notice these dotted lines on the handle template.

 

cut the handle

Now cut one of the handle pieces to match those lines. There are two cuts. And only do this on one of the handle pieces.

 

Ok, Let's glue the sword together

place handle piece down

Place the full handle piece down on your table. This is the handle piece that doesn't have the treasure chest cut away.

 

The stack is glued

Now glue the three sword blades parts right on top of it. Keep the glue or hot glue away from that rectangle that is the treasure chest.

 

The final handle piece

Now glue the partial handle piece right on top.

 

Once all these pieces are glued together you should clean up the edges and the seams. You can use a hobby knife for the rough work and some sandpaper to smooth the edges out.

 

Trim edges    Sand edges

 

 

The treasure chest lid

NextOkay! Let's continue and I will show you how to put on the treasure chest cover so that you can open and close it.

 

 


 

California Costumes Women's South Seas Siren Costume

The costume includes a dress with a handkerchief skirt and head tie. Available in adult sizes Small, Medium, Large, and X-Large. Items not included are jewelry, sword, and boots. Pair up with the Rogue Pirate for a couples look.

 

 

 

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