Quote Tanuki-Otaku:
My katanas form my zoro cosplay are made from wood, it is a lot easier than people think it is to actually use wood (I was originally going to use cardboard XD)

Here's a link to my swords - http://www.cosplayisland.co.uk/costume/view/20062

But if you are determined to not use wood I would suggest materials such as plaster of paris (this can be very heavy though) or styrofoam (Very light but this can be very brittle when thin and can be desolved by many spray paints..... I learned all this the hard way in GCSE Graphic Products).

You could try foam board (strong yes, but a B*tch to cut if you don't own a craft knife.... and when you do cut it with a craft knife, you have cut the line severeal times to get a clean cut)

Hope, I've helped... there are people more educated in how to make swords but hey just thouigh I'd share what I've found out

Quote englicana:


Ha! Zoro is actually the cosplay I need to make the katana's for! XD (yours is epic btw).
Did you make the sheaths from wood too?
How much did it all cost? I'm worried that it's going to cost an insane amount...

Quote Tanuki-Otaku:
The main sword and guards are made from wood and the sheaths are made from conduit (the stuff you put wires and cables in to tidy up a room) the cost of these materials from B&Q came to around £12 at the most.

The handles are part of the main wooden sword and the fabric is a bandage wrapped around the handle area to give comfort and then the details either glued on or tied the proper way for a katana, here's a tutorial thats really easy to follow - http://chioky.deviantart.com/art/Handle-Wrapping-Level-4-106018542 I'd say the fabric cost around £2 at most (get offcuts )

The sheaths are covered in a fabric sleeve that is hot glued on, the fabric whas what I had left over from the actual costume.

Then there's the cost of acyrlic paint ( use this as it goes on the wood easly after the wood had been undercoated)

When do you need to have the swords done by? And are you going to the cosplay cruise or LFCC? I could show you in person my swords if that would help you ^_^

X

Quote englicana:


Ah awesome! I might try making them like that then. I'm not really sure when I need them for. It was going to be for October Expo but things keep changing so I'm not sure anymore XD

I'm going to LFCC so you could show me then? That'd be epic =D

Quote Junta:
Just something to consider during planning/building of props - if you're taking a prop katana to any event other than Expo, you'll have to look out for the props rules of the relevant event, which are often far tighter than those at Expo. Usually hardwood is banned outside of masquerades; its an insurance thing mostly.