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Make Excalibur from King Arthur: The Legend of the Sword

This is a tutorial where I show you how to easily make Excalibur. And I give you the template which makes it even easier.

You are going to just need a few basic supplies including two sheets of foamboard. And you can substiture that with cardboard if you need to.

The Template is here


Excalibur large banner



Overview of the Project

This is a replica of the sword used in the movie King Arthur: The Legend of the Sword. And it is made out of foamboard. And while it is a replica it is not exactly the same. I took some liberties including making it a little bit smaller so it would be easier to make and less expensive.


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.




Tools and Materials:

  • 2 Sheets of foam board (Elmer's Acid-Free Foam Boards)
  • Some kind of thin black string, or black shoelaces or black leather cut into strips. This is to wrap the handle.
  • Glue of hot glue gun
  • X-acto knife or sharp hobby knife
  • Paints: Silver, Gold, Red, Black
  • Mod Podge to seal it all (optional) Mod Podge Waterbase Sealer
  • The Template (right here)

Would you consider a donation of $1 to support my work? Paypal makes it very easy and safe. Click here to donate $1 - Every little bit helps Will to keep making great tutorials and templates. Thanks!


Print up the template and cut the parts out.

Cut out the template parts


You end up with seven template parts.

The seven template parts


Take parts labeled as 1 thru 4 and tape them together to form the sword template.

Tape together 1 through 4


Take that sword template, place it diagonally on a sheet of foam board and trace it. Do this twice which means doing it a second time on a second sheet of foam board.

Place template on foamboard and trace it


In the template there three more pieces. One is the guard and two are for the pommel. Trace two copies of each of these on foam board.

The traced parts

This picture just above shows all the pieces you have traced. And there is one more piece. It is another full sword piece that you had traced onto a second sheet of foamboard.


Now go ahead and cut out all the parts.

Cut out the parts


Cut out the parts



Will's Tip on Cutting Foam board: Don't try to cut all the way through it in one swipe. Use a really sharp blade and make three passes. the first pass just cuts the top layer of paper. Second pass cuts the foam and the third pass cuts through the bottom layer of foam.


You end up with eight pieces. Now let's glue it all together. Start out by gluing the two large sword pieces together- one directly on top of the other.

Glue together the blade parts


You can use any type of glue that works on paper. I am using a hot glue gun.


NextLet's continue



Foam board

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.


X-acto designer series knife #1 blade