How to Build a samurai katana sword out of cardboard
The katana (also known as the samurai sword) originated in Japan's Muromachi period (1392–1573). These curved blades are known worldwide for their elegance and craftsmanship. But if you can't afford your own antique model you can create your own reproduction using junk you've probably already got in your garage.
5 sheets of cardboard, 4 inches by 30
A saw to cut out the Katana shape.
Sandpaper, medium grit.
A roll of clear packing tape.
Black, blue and red electrical tape.
1. Cut out six sheets of cardboard in 4 x 30 inch pieces, three pieces where the grain of the cardboard runs one way, three pieces where it runs the other way.
2. Take two pieces with opposing grains and apply wood glue to both, using a brush to spread it out. Repeat this process until you have the six sheets glued together.
3. Pile books or other heavy objects on top to weight the cardboard down and smooth it out. Leave it overnight.
4. The next day, draw the shape of the katana on the cardboard. Use this as a pattern when you cut out the katana.
5. Apply a layer of carpenter's glue on the edges of the cardboard katana, covering the corrugations. Now again let the project sit overnight.
6. Now it's finally time to decorate the katana. You can either use paint, or you can decorate it with aluminum foil and tape, using the clear packing tape to protect the foil.