A katana is an oriental-style, martial arts sword. These swords have been made by master craftsmen for centuries. Fortunately today's tools allow you to make a decent replica of this traditional weapon. A rotary tool or bench grinder will give you a shaped, sharpened and polished blade for your katana. Then you can do some creative woodworking to fashion a handle for your homemade sword. Once you learn the basics of this process, only your imagination will limit the complexity of your handle design.
Lay your katana on top of the dowel. Center the holes in the tang of the sword along the length of the dowel. Mark the dowel at the location of each hole in the tang with your fine-tipped marker.
Remove the sword from the dowel. Hold the dowel firmly with one hand. Use your other hand to drill through each mark on the dowel with the 3/8 inch bit.
Hold the dowel so that the holes through the wood are at a 90-degree angle to the blade of your band saw. Push the wood gently into the spinning blade of the saw to cut the dowel into two even pieces.
Place half of the dowel on each side of the tang of the sword. Slip the female half of a rivet into each hole in the dowel. Flip the sword to expose the empty holes in the other side of the handle. Slide the male end of a rivet into each hole. Strike each rivet with your wooden mallet to secure each fastener and lock the handle in place.
Install the sanding wheel onto your rotary tool as instructed by the manufacturer. Smooth and shape the handle with your rotary tool.
Remove the sanding wheel and install the engraving bit in your rotary tool. Engrave a diamond pattern into both sides of the handle.
Wipe the dust off of the handle with a rag. Place the sword onto the dust sheet. Cover the blade of the katana with painter's tape.
Coat both sides of the handle with three coats of spray stain. Coat the handle with three coats of spray polyurethane. Let each coat dry for 2 hours before the following application. Allow the katana to dry for 24 hours after the final coat of polyurethane. Remove the tape from your katana blade.
Work gloves, safety glasses and hearing protection are required when using power tools. A dust mask and proper ventilation are necessary when using any type of spray chemicals.