A while back I wrote about some rupees I made for a Legend of Zelda musical. The group doing the musical is called The League of Extraordinary Thespians, and I made a few more props for them, such as Link’s Master Sword.
The musical is based off of The Ocarina of Time video game, so first I had to find some accurate reference images from the game. From those, I drew out a paper pattern for the blades.
After cutting the pattern out of plywood, I made another pattern to find the bevel on the blade. I was working on three swords (one for Link, one for Dark Link, and one for a lobby display) so taking the time to make these patterns saved a lot of time in the long run.
I used a rasp and block sander to shape the blade.
I turned some of the handle and guard parts on a lathe. The quillon block (otherwise known as the écusson) is just a slice of PVC pipe.
For the rest of the detail on the guard, I used pieces of MDF which I shaped with my belt sander and fine tuned with a Dremel.




