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.

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:

• 1 sheet of foamboard Here it is on Amazon if you want to order it: Elmer's Acid-Free Foam Boards, 20 x 30 Inches, 3/16-Inch Thick, Bright White, 2-Count (902015)
• The Template
• Hot glue gun or glue
• Sharp hobby knife
• Paints: Red, Silver, Black
• Glue stick (optional but nice)

To make the Easy Cast Egg Jewel:

• 1 egg
• Blue food coloring
• 1 box of Easy Cast (Environmental Technology 8-Ounce Kit Casting' Craft Casting Epoxy, Clear )
• If you don't want to make the easy cast egg you just need some paper and thin cardboard or card stock to make the paper jewel.

Let's Get Started:

Print up the template and cut out all the pieces.

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.

Now 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.

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.

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.

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.

Okay! Let's continue

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

Watch the Video Tutorial:

SUPPLIES AND TOOLS

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

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

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