How to Make Wooden Ninja Swords

The simple ninja-to is second only to the black outfit and mask when it comes to defining the ninja. A simple, workman-like Japanese sword that is shorter and handier than the more traditional katana, the ninja-to was every bit as practical and to-the-point as the ninja fighters themselves. Fashioning a wooden ninja sword for use as decoration, in a costume, or in a sport like kendo requires on a few specialized tools, the right materials and a bit of patience.

Things You'll Need

• Wood pieces suitable for a handle/blade and a crossguard
• Hand saw
• Coping Saw
• Sandpaper and hand sanding block
• Wood glue
• Stain and lacquer
• Woodworking knives
• Leather thong (optional)

Instructions

1. Select your wood. Most wooden swords are made out of the pleasant-looking rosewood, but if that is not available, any hardwood will do. You will need two pieces: one for the sword and one for the crossguard. In the ninja-to, the crossguard is a square piece that fits above the handle and protects the hand.

2. Shape your sword. Unless you have access to a lathe, you will need to do this by hand, carving and whittling the sword. Using pictures of a real ninja-to, carve the one piece of wood into the shape of the blade and handle, then sand it for a good finish. Make sure your handle is wider than the sword blade. That's important in fitting the crossguard of your wooden ninja sword.

3. Using the coping saw, carefully measure and cut a hole in your square crossguard. The crossguard will be sliding down the blade, stopping at the handle, so it should be measured for that part of the sword (presumably the thickest part). The fit must be exact, so take your time.

4. Slide the crossguard down the blade and fix it into place above the handle, using wood glue or another carpenter's adhesive that is even stronger.

5. Protect your sword by staining and lacquering it. This will also improve its appearance; but the main point is that, after all that careful manual labor, you will want to protect your wooden ninja sword from the elements. Choose the desired stain, apply it with a brush and then apply five layers of lacquer as a sealant. You will want to use that many layers, since this is a wooden sword that will probably be used to whack things.

Tips & Warnings

• Working with knives should always be done with the greatest of care. Wearing thick leather gloves is recommended.