Lego Ninjago Sword of Fire

My son recently asked me if I could make the Sword of Fire from the Ninjago TV show (and Lego sets). Being the Maker Dad that I am I said:

Sure!... Maybe... Probably

Going and finding the sword in our bin of Legos (or Lego Bricks if you want to be technical) I figured that it would be a fun build to put together for him. It's an easier project, but definitely time consuming.

Want to see how to put one together? Let's Ninjagoooooooooooo!

The materials I used for this build were:

A piece of 2x4

Yep... that's it.

The tools I used for the build: (with affiliate links)

Miter saw - https://amzn.to/2MXuBQq
Scroll saw - https://amzn.to/2Vi84lf
Clamps - https://amzn.to/2XDyJq4
Chisels - https://amzn.to/2tNRs4F
Dremel - https://amzn.to/2tNS769
Micro Sander - https://amzn.to/2KszX46
Gold spray paint - https://amzn.to/2MUDpXg
Clear gloss spray - https://amzn.to/2IV61ub

I took a picture of the sword and brought it into Inkscape. I used the pen tool and traced out the outline of the sword, then used the edit path tool and matched the curves of the sword.

I measured my son's hand and figured a good size to fit him, then scaled the outline I created to match.

I printed the outline out, taped it together, then cut it out.

*insert a 2x4 Lego brick joke here*

I traced the outline onto a piece of 2x4, then cut it to size. I took it to the scroll saw (a bandsaw would work better but I don't have one). I cut out the outline of the sword, then using the picture again as a reference, I drew all the designs on each side of the sword.

Here comes the fun part... and the time consuming part.

I marked out the center of the handle, then drew a circle around the edge of the handle.

Then... carving. Lots and lots of carving.

SIDE NOTE: Carving pine is... terrible. A better option would be any kind of hardwood. Any kind. Pine is just not carving friendly.

After getting the designs of the blade done, I carved out the dragon face on the handle.

Again... time consuming.

The last part was to carve the designs into the handle.

Is that going to be stuck inside your head now?! You're welcome.

I took a micro sander to sand down the larger flat areas on the sword, especially on the blade, and get the whole thing sanded down.

For the fine details of the sword I took a sander bit on my Dremel and sanded down all the curves and nooks of the dragon's face.

I took some gold spray paint and painted the sword. I added 2 coats to each side, letting them dry inbetween coats.

To finish off I took some gloss clear coat and, again, put 2 coats on each side of the sword. I allowed each coat to fully dry between each coat.

Now that it's done, enjoy! Go fight some evil snake lords, or skeleton armies, or whoever needs a good fight with someone wielding the legendary sword of fire!

Now you know how to build it, see it being made!

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