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How to Make the sword Zar'roc from Eragon


This is a fun and easy foam board project and all you need in terms of the foam is one sheet. And this project is a bit unique in that I use a new technique that I have never tried before. I use easy cast to make the jewel at the end of the pommel.

The template is right here

I also have a video tutorial for this project at the bottom of the page.


Here is the completed sword


And here is a close up look at the handle and the jeweled pommel.

Zar'roc the sword


The egg

The two pictures above show the sword with the easy cast jewel in it. But if you don't want to do that process I have a paper jewel for you in the template. Cut that out, fold it into a jewel shape and install it into the pommel.






Materials Needed for this Project:

To make the Easy Cast Egg Jewel:

Let's Get Started:


Cut out the template pieces


Print up the template and cut out all the pieces.







Assemble the template

There are five template pieces that make up the sword. Tape those five pieces together so they make a complete sword shape. From left to right they are 1,2,3,4, and 5.




Trace the template onto foam boardNow we are going to use that template to trace two swords onto foamboard. Each sword has two pieces. So we end up with four pieces here. Let me explain.

Foamboard is only around 30 inches long and our sword is longer so we have to make the pieces to fit the foamboard then glue them together.





The paper template

Here is how we trace these pieces.

On the template is a "B". See it in the picture? Trace everything to the left of it onto foamboard. That will be one piece. Trace everything to the right of it onto foamboard. That will be your second piece.

Now, repeat this process with the "A" that is marked on the template, trace the left of it piece and the right of it piece.



The various pieces

So, this is what we end up with. Four sword pieces. Notice that the foamboard sheet also has room for the two dragon hilt pieces.





Cut the foam board

Go ahead and cut all those pieces out.








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.


So let's glue together the sword. Start by laying out the two "A" pieces like this.


The glue the two "B" pieces right on top of those "A" pieces.


NOTE: When gluing the sword together do not put any glue on the tear drop shaped pommel. Leave that section unglued. This is because later in the tutorial we will need to open that up and fit the gem in there.







NextOkay! Let's continue



Environmental Technology 8-Ounce Kit Casting' Craft Casting Epoxy, Clear



Watch the Video Tutorial:





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




xacto knifeX-ACTO Z Series #1 Knife with Cap (XZ3601)






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