Make a Ninja Katana Sword 

The Katana is the Samurai secondary weapon used between 11th-18th centuries (some dates differ, and other include WW2 era Katana). The Katana, along with the Kama (sickle) and wakizashi (short sword), and sometimes the nari (spear), were the basic weapons of most Japanese warriors.. This only shows you how to make a basic sword.

Steps

  1. Decide whether you want a one-handed sword(wakizashi), two-handed sword(nodachi), or a hand-and-a-half sword(katana).
  2. Start with a rectangle of metal. About {{safesubst:#invoke:convert|convert}} is the normal size. High carbon steel between 1055 and 1075 is the optimum material for weaponry, but others like Damascus Steel are also renowned for their ability.
  3. Cut either a quarter of a circle or 45 degree angle out of the tip with torch cutter.
  4. Make a hand guard (tsuba). Start with a piece of metal and drill over lapping hole in the middle until you have a spot wide enough for the blade. Ensure there is a snug fit so the guard does not slide.
  5. File off the "bur", or the spare metal inside the hole after cutting.
  6. Weld or glue the guard to the thread of the sword (the part of the sword which will be covered by a handle).
  7. Add a wooden handle (tsuka) or leather wrapped conformed to your liking with wood glue.
  8. Grind the blade to a sharp edge.
  9. Wrap the handle with nylon or leather, whatever you find!

Alternate Method

  1. Find a good material, such as PVC, to make a synthetic sword not made of metal.
  2. Mark off a spot to cut the dowel. (place for hand guard)
  3. Cut out a circle of wood or another material, and glue the two dowels to the opposite side of each other.
  4. Sand the sides of the longer end so it's flat on the sides and rounded or pointed on the tip.
  5. To make a sheath, find some tubing or leather, and cut it off about an inch longer than your sword.
  6. On the extra inch, sand the tubing to the shape of your sword's tip. This will be the closing of the sheath.
  7. On the sanded end of the tube, take a small piece of wood or other strong material and cut and insert it into the tubing.
  8. The sword and sheath are finished!



https://www.youtube.com/watch?v=qLmzeGV1sQo

Tips

  • Only sharpen one side! the other side is called the "false edge", which was traditional used to push on in close quarters to increase power.
  • Use high quality metal for the blade, such as high carbon steel.
  • Make the handle oval shaped with curves along the side for grip, as well as to aid in edge alignment(explained in video above).

Warnings

  • This sword is sharp after being grinded. Do not slide it across an object you do not wish to cut.

Things You'll Need

  • 1 rectangular piece of metal.
  • 1 square piece of metal.
  • Grinder or sword sharpener(sharpening stone).
  • Torch cutter.
  • Band saw.
  • Glue, and/or welder
  • Drill press.
  • Clothing for handle.
  • 2 pieces of wood.
  • 1 pair of safety gloves (that's per person)

Related Articles

Acknowledgements

  1. This sword type is actually a wakizashi due to its length and blade angle.
  2. This sword was used by ninjas.

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