I carved out the grooves on the opposite sides. With the grooves carved out on one side of each piece, I cut them out on my bandsaw. Without a guide, it’s hard to direct a Dremel it tends to wander. Someone skilled with chisels could just carve these completely out, but I just needed starter routes for my Dremel rotary tool to ride along. Using a sharp chisel, I carved out some “guide” channels. Then I drew in lines where the beaded curves would go. I attached two templates using spray adhesive then scored the outline of each with an X-acto knife. I chose birch because it is soft enough to shape and carve and has a light color for painting, but it’s not as soft as pine, which tends to splinter. I made these out of 1/2″ (12mm) thick birch lumber. I started with the most challenging part: making the two curved hilt pieces. But mostly, carving the curved hilt would be difficult and cumbersome. It might be possible to make the blade and hilt out of a single board, but it would need to be pretty wide. The Master Sword is all about its ornate details and Zelda tradition and legend.Īfter a lot of consideration, decided the best approach was to make it out of three pieces: the blade, the handle and the hilt. That one was a fairly simple shape and I could make it out of a single board. I quickly realized is would be much more challenging to make a Legend of Zelda Master Sword than my previous sword, Jason’s machete from Friday the 13th. I liked this version, so based mine on it. Most have a bluish purple handle and hilt, but some are black. Not knowing a whole lot about the Zelda games, I looked at a lot of examples of the Master Sword and discovered that there is a bit of variation among them. Since I don’t have any of that, I made this one almost entirely out of wood and it gave me an opportunity to use a lot of different tools and techniques.

Most prop-making is done with foam and other materials and shaped with CNCs, laser cutters, and 3D printers. Mostly, it’s fun to try to come up with ways to replicate the details. I always find prop-making to be super fun and enjoyable. A couple months ago, my son suggested I try to make a Legend of Zelda Master Sword which I added to my ever-growing project list and finally got around to it this week, just in time for his birthday.

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