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Toki-Jin tutorial

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Step 1: select a board that is ½” thick and the desired width of your blade, and about 3-4” longer in length.

Step 2: Draw out the pattern for your sword and guard, you can shade in the areas that are going to be cut away to make it easier to remember if you like. (Make sure that you don’t make the ring on the pommel bigger that the shoulder section where the guard sits, if you do then the cut-out in the guard will not fit onto the handle.)

Step 3: Cut out your pieces and sand down the rough edges to your lines, and draw a line the length of blade down the center of both the blade edges and on both faces.

Step 4: now cut out the center of the guard, use the lines you drew to act as a guide for beveling your blade and drill out the sections of the pommel. (For cutting the hole in the guard I recommend drilling a few holes that are the same diameter as the cut out to remove most of the material and using a file or an exacto knife to remove the rest.) (For the pommel I recommend using a Boring bit and drilling 1/8” deep, then using a 1/16” drill bit drill all of the way through your piece. Turn it over and use the boring bit again then with a ¼” drill bit make the center hole bigger.)

Step 5: slide your guard on and glue it in place.

Step 6: out of some scrap pieces of material cut four pieces to go above the guard and two to go under it. (One piece for each beveled edge of the blade and one piece for both sides of the handle and glue them in place.) Note. Make sure that the pieces for the blade stick out past the edges of the blade when they are glued in place, after finishing this will help to make it look like it goes all the way around the blade. After gluing them in place use some wood filler to fill in any cracks wait for it to dry and sand it smooth.

Step 7: tape off sections of the blade and paint them your desired colours, then after its dry wrap the handle with cord and you are done. You now have a finished sword to use for Halloween, Cosplay or display.
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