For Halloween, I went to a really fun costume party as a Samurai. I made a kimono and hakama, but as I was trying on the costume, I thought: “it’s just not going to look like a samurai without a katana.”
What to do next? Make a wooden katana, of course!
I found a piece of lumber which was of an acceptable length (roughly a yard) and sketched up the basic outline of a katana, which is pretty basic, just a simple sword with one straight edge and one curved slightly at the end, because it’s a single-bladed sword.
So, I just cut it down nearly to where I wanted it with the saw I had available (which is to say, a circular saw) and then used a mallet and chisel to define the hilt a little better. The last bit of smoothing out was done with a razor blade and a power sander (because hand sanding on something so big is tedious, at best) until the blade side was defined and there were no splintery bits left.