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This will be my first ever cosplay as well as my first prop creation. I decided to do Kurosaki Ichigo from Bleach because the first release of the Zangetsu seems simple enough to make. Can anyone give me some pointers or maybe even some full-on instructions?

Use either a plank of wood or Ply wood and use a jigsaw to cut out the shape. Use a woodrasp (or wood file) to make the blade. Spray of primer, sand it a llittle, and top it off with Hammard metal gray paint. DONE!

Now what about the cloth on the handle? What would be the best way to secure that. Also, is plywood the best choice since it has a tendency to warp?

For the Cid Spear I made, I used Medicle adheisive tape to use for that.

For my Buster sword, I used Red Electricle tape. They do sell them in colors, like white!

I'm thinking the plywood might be a little too heavy for a sword that size. Any alternatives?

I made a large Buster sword out of Pine, it came to be around 5lb. For that, depending on your size, around 3-5lbs. The hard part was holding it away from your body, the flex weight was mad heavy, but really durable and fairly easy to swing.

Try Pine planks and thining them up. Or I could build one for you if yours isn't turning out good.

just b/c you're trying to make that . . . YOU ROCK! *huggles*
xD

Sorry I'm of no help, I'm useless *tear*

Actually I just got into making the swords from Bleach myself, so I may just be of some help to you. ^_^ Personally, I made mine from cardboard, a wooden rod, and some duct tape. It may sound like it will not work, but the swords I've made are very strong and very light.

http://cosplaymaverick.deviantart.com/a ... t-93837942 (Zabimaru=complete)

http://cosplaymaverick.deviantart.com/a ... t-96493424 (Zangestu=in progress)

If you want I can pm you with exactly how I made these.

~Toboe~