Time Required :
About an hour
Advanced
Advanced
You're definitely experienced.You've tried it all, and you're looking for a challenge!
Step 1
Click here and here to print the templates from michaels.com.
 
Handle: Measure and cut the black adhesive foam sheet into two pieces. The first piece should be 5" x 9", and the second piece should be 1" x 9". Set the second piece aside.
 
Remove the backing from the 5" x 9" piece of adhesive foam. Place the short edge of the foam against the length of the dowel, 1" down from the dowel’s end.  
Step 2
Roll the foam sheet around the dowel, keeping it as straight as possible, until it is completely wrapped around the dowel. This will be the handle of the sword.
 
Wrap one red and one silver chenille stem around the length of the handle. Use very narrow strips of bronze Duck Tape® to fix the stem ends in place just above and below the ends of the handle. Use the image as a guide. 
Step 3
Guard: Evenly cover a 6" x 12" section of the black 12" x 18" foam sheet with strips of bronze Duck Tape®. Overlap the strips very slightly, so that the foam sheet does not show between strips.
 
Turn the sheet over and repeat the previous step to cover the other side of that 6" x 12" section of foam. 
Step 4
Trace the guard pattern onto the taped portion of the sheet and cut it out.
 
TIP: Gently bend the cutout piece to curve it into a U-shape. This will help it to bend properly when it is placed on the sword.
 
ADULT: With the X-ACTO® knife, cut an “X” 1" from each end of the guard. Use the “X”s marked on the pattern piece as a guide. 
Step 5
Push the long end of the dowel underneath the handle through the “X” on the wide end of the guard.
 
Gently bend the length of the guard into a curved shape and push the end of the dowel above the handle, through the “X” on the narrow end of the guard. 
Step 6
Remove the backing from the 1” x 9” strip of black adhesive foam. Wrap this strip around the very top of the dowel, above the guard, until it is completely rolled around the dowel. This will hold the top of the guard in place and finish the top of the sword.
 
Blade: Evenly cover a 5" x 18" section of the gray 12" x 18" foam sheet with strips of silver Duck Tape®. Overlap the strips very slightly, so that the foam sheet does not show between strips. Do not cover the other side of the foam. 
Step 7
Adjust the blade pattern to the length you desire. To make a sword like the one on this page, increase the pattern’s size until the blade is 15" long.
 
Trace the blade pattern onto one side of the taped portion of the sheet. Cut it out and set it aside. 
Step 8
Place the pattern again on a portion of the gray foam that is not covered by silver tape. Be careful not to flip the pattern as you move it to the gray foam. Trace and cut out this second piece, then set it aside as well.
 
Cut four 18" lengths of silver tape, and lay them down, sticky-side up, on work surface. As before, overlap the strips slightly, creating a rectangle of tape. 
Step 9
Lay the second, gray foam blade shape flat in the center of this sticky rectangle. Again, be careful not to flip the blade shape as you move it. Make sure that that there is a border of tape at least 1” long all around the blade shape.
 
ADULT: Using the X-ACTO® knife, cut through the tape all the way around the blade shape, leaving a border of tape that is approximately ½" wide. 
Step 10
ADULT: With the knife, make vertical slashes in this border, from the foam shape to the tape edge. The cuts should be approximately 1" apart.
 
ADULT: Cut additional slashes at the most curved parts of the blade, reducing the space between cuts to ¼". This will help the tape border to fold down evenly over both sides of the blade. Set this second blade shape aside. 
Step 11
Assembly: Place the dowel with handle attached next to a second dowel so that they overlap. Slide the first blade shape (the one without a tape border) underneath the dowels, to see how much they will need to overlap. To make the sword in the project image, which has a 15" long blade, we overlapped the dowels by 5".
 
TIP: Make sure the foam blade tip extends at least 2" past the end of the second dowel.
Secure the dowels together with masking tape, being careful to preserve the necessary overlap as you wrap the tape. 
Step 12
Secure the dowels together with masking tape, being careful to preserve the necessary overlap as you wrap the tape.
 
TIP: Mark the top and bottom of the overlap on each dowel so that it is easy to keep them positioned correctly while you tape. 
Step 13
Lay the first foam blade shape (the one without a border) with its silver tape side down on the work surface. Place the handle and dowels on top so that the base of the blade butts up against the bottom of the guard.
 
Use silver Duck Tape® to secure the dowels onto the blade shape, all along its length. 
Step 14
Flip the blade and handle over so that you can place this first blade shape exactly on top of the second shape. Take special care to make sure the blades match up as perfectly as possible.
 
TIP: Trim the shapes if necessary to get an exact match.
 
While holding the two blade pieces against each other, begin pulling and wrapping the border sections from the second blade over the edge of the sword and down onto the first blade. Be sure to keep each section of the tape border as smooth and tight as possible as you wrap. This will seal the edges of the two blade pieces together into one piece. 
Step 15
Project Note: For materials and instructions to make the Pirate Halloween Costume, go to michaels.com and enter 81909 in the search field.
 
Share your project photos with #MadeWithMichaels 
Materials

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Materials
 

    Products

  • You’ll Need: 1
    Item # 10196229 
    $5.49
    Add to cart options
  • 876270958
    You’ll Need: 1
    Item # 10032002 
    $0.99
    ea.
    • Color: Black
    • Size: 9" x 12" in
    • Color: Black
    • Size: 9" x 12" in
    • Color: Black
    • Size: 9" x 12" in
    Add to cart options
  • 990613439
    You’ll Need: 1
    Item # 10041223 
    $1.99
    • Color: Multi
    • Color: Multi
    • Color: Multi
    Add to cart options
  • 995912840
    You’ll Need: 1
    Item # 10597484 
    In Store Only 
    $0.99
    • Color: Black
    • Size: 12" x 18"
    • Count: 1
    • Color: Black
    • Size: 12" x 18"
    • Count: 1
    • Color: Black
    • Size: 12" x 18"
    • Count: 1
    Add to cart options
  • 995912840
    You’ll Need: 1
    Item # 10290390 
    In Store Only 
    $0.99
    • Color: Gray
    • Size: 12" x 18"
    • Count: 1
    • Color: Gray
    • Size: 12" x 18"
    • Count: 1
    • Color: Gray
    • Size: 12" x 18"
    • Count: 1
    Add to cart options
 
Tools

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Tools
 

    Products

  • You’ll Need: 1
    Item # 10446639 
    $5.39
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  • 845160372
    You’ll Need: 1
    Item # 10338068 
    $1.79
    • Color: Black
    • Count: 1
    • Color: Black
    • Count: 1
    • Color: Black
    • Count: 1
    Add to cart options
 

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You’ll Also Need
  • Computer
  • Printer
  • Masking Tape, ½""
  • Pen/Pencil
  • Ruler
  • Duck Tape® Roll – Bronze (sku 10457507)
  • X-ACTO® #1 Precision Knife (sku 10223576)
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