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Make a Pirate Cutlass with a secret treasure chest

This is a tutorial showing you how to make a pirate cutlass out of foamboard or cardboard. It is an easy project to make and it uses just one sheet of foamboard.

And right in the sword it has a secret treasure chest compartment where you can store your pirate treasure. It could be gold, silver, an eye patch, a treasure map or something else!

I also give you the template for it. You print up the template and use it to make your cutlass. The template is right here.

This project also comes with a video. It is at the bottom of the page.

Will has a youtube channel with over 700 videos on projects you can make. Check it out right here





Pirate Cutlass



The secret compartment in the sword

This sword has a secret compartment that you can store your pirate booty in.








Earn a Certificate of Contribution!


If you make this project email me a picture! I will email you a certificate of contribution from stormthecastle.com You can print it up and hang it on the wall.




Materials and Tools:


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Let's Get Started

Print up template

Print up the template and cut out the three pieces.

You also cut out the rectangular shape for the treasure chest and cut out the space between the handle and the knuckle guard.






Tape template together

Tape the three pieces of the template together like this. And notice that I have cut out the two sections shown with the arrows.






Place and trace on foam board

Place that template on foam board or cardboard and trace it. Be sure to also trace those interior cut out sections. Do this three times. Trace three of them.





The three sword pieces

Here are the three traced swords.






Cut template on dotted line

Now cut the template on the dotted line. This gives us just a handle piece.








Trace two handles

Now use that handle piece to trace two onto the foam board.








The two traced handlesHere are the two traced handle pieces. Notice that the area around the handle (knuckle guard) is traced but the rectangle for the treasure chest is not. No need to trace that treasure chest.

NextOk, We are doing great. Let's continue with the tutorial





The Video Tutorial is here:


Elmer's Acid-Free Foam Boards, 20 x 30 Inches, 3/16-Inch Thick, Bright White, 2-Count (902015)

If you are looking for high quality, archive quality or you are looking for a backing for photographs you should use an acid free foam board It is more expensive per sheet though.


Ace martial Arts Supply Regal Pirate Cutlass

  • Overall length: 27" blade length: 19.5" handle length: 7.5'
  • Handle material : black finished steel w/cord wrap
  • Constructed from 440 stainless steel with sharp "Saw back" dual blade



Forum Noveltis Pirate Cutlass

This pirate sword has a curved silver blade and an antique gold finished handle. Measures approximately 16" long.




Make Deadpool's Katanas and the Holster

You can have swords, and wear them, just like Deadpool does. And for fun I also give you the template so you can make a miniature set like I made for the dragonslayer. Make Deadpool's Katana and holster





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