Spartacus: War of the Damned Inspired Aluminum Prop Sword

I am a superfan of the series Spartacus. I am also looking to build cosplays based on my favorite characters. This prop sword is inspired by Spartacus' sword from War of the Damned.

Aluminum Flat Bar (2"X1/8"X36")

Poplar Board (3"X1/5"X36)

EVA Foam (1/8")

Furniture Plastic Foot Cap

Wood Stain

Flat Black Spray Paint

Hot Glue

Silver Acrylic Paint

Find high quality photos of your desired prop for reference.

Draw the design onto the flat-bar and cut it out with a grinder or whatever you have available to cut metal. Trace the basic handle shape onto the poplar and cut it out.

Grind the edges down. Attach the wood pieces by screwing them together with the aluminum sandwiched between the wood. Sand the wood down to the aluminum and contour and smooth the edges to desired form.

Use the EVA foam to create the raised piece on the cross-guard. Use a file to cut a channel on the pommel and cap it off with the furniture foot cap. Hot glue the pieces onto the hilt group. Smother it all with paper or wood glue to seal it all in (don't put glue on the wood part of the hilt).

Mask the wood part of the hilt, and the first 8 inches of the blade. Spray the flat black onto the cross-guard and pommel. Let dry, and then dry brush silver over the black. Remove the tape and stain the wood part of the hilt. Dust the whole thing with flat black spray paint and seal it all with matte clear coat.