- 1). Print a picture of your sword to use as a reference. Cut a large, 4-foot piece of paper from a paper roll. Draw a life-sized version of the sword, using the picture as a reference for the shape.
- 2). Cut out the sword drawing. Tape the sword cutout onto the foam board and trace around the cutout with a fine felt-tipped pen. If the sword drawing has intricate designs on it, remove the sword cutout and then cut out the designs. Tape the designs to the foam board and trace them.
- 3). Cut the sword out of the foam board with the foam board hand saw.
- 4). Glue the designs onto the main blade of the foam board sword.
- 5). Sand down the edges of the sword with fine grit sandpaper to make them smooth.
- 6). Paint the sword with an even layer of foam grade primer paint. Paint the blade with silver paint. Paint in details on the hilt or blade with acrylic paint.
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