Hey everyone.

Task: Make Trafalgar Law's Sword from One Piece.

I am a complete novice when making prop's for cosplay. I was going to make the sword from wood, but the convention I'm going to will not let me.

I want to make a good looking sword out of safe materials. As for it's design, I want it about 4ft-5ft, and I only want it to be the sheath and handle. No blade has to pull out.

Really have no idea where to begin, or what cheap materials I can use. Could anyone help?

Thanks in advance ^^

Well considering all things, Trafalgar is also on my list only I plan on drawing him too.

My honest opinion is to get a huge sheet of Plastazote from your rubber/foam dealer and a metal curtain pole.

As a novice goes- I like to use recyclable and basic easy to use materials.


Cut your patters out with paper and then align it to the pole,

Then make the sword.

However if it's just the sheet, just buy 10mm thick Plastazote and x 2meters

Cut out the necessary panels to make the sheath, stick them together with contact glue. Wait for the glue to get tacky before putting it on and then do the same for the hilt

Sounds vague. Wish I could show you

Reference pictures are always a good idea as generally people (especially me) won't know what you're talking about. I was in a good mood though so I googled it. It looks similar to a Katana.

As Manticore was saying foam, foam and more foam. This Khaos Kostumes tutorial will show you how to make a katana out of plastizote, so it'll be pretty much the same idea just longer. This would also mean you could make the blade and a sheath if you wanted or just make the sheath out of foam.

Hope this helps