How to Make a Cutlass Sword

Written by sarah coennen | 13/05/2017
How to Make a Cutlass Sword
Cutlasses were popular with pirates. (Pirate image by Dubravko Grakalic from

Making your own swords can be both fun and beneficial. This is especially true if you are making them for your kids because you will know how safe they really are, and you can feel comfortable knowing exactly what materials were used in the construction. Cutlass swords are swords that have a curve in the blade. They are not as long as a regular sword, and also have a two-part hilt, in which one part goes over the hand as a protector.

Trace out the cutlass and hilt on two pieces of cardboard. Do not worry about the protective covering of the hilt on the sword just yet.

Cut out both drawings of the cutlass sword. Place them side by side. Measure and cut the dowel rod if needed so that it fits the full length of the cutlass. Wrap both ends in tape so that it is cushioned.

Tape the dowel rod to one side of the cutlass sword. You only need to do this on one cutout of the cutlass. Place the other cutout on top of the dowel rod and tape the two sides of the cutlass together.

Wrap the blade of the cutlass in aluminium foil. Do your best to not get wrinkles in the aluminium foil. This will take some time and patience, but you can do it. Wrap the aluminium foil in clear packaging tape so that it does not get ripped.

Colour the hilt of the cutlass if desired with paints and/or coloured markers. After the hilt has dried, cut out a piece of cardboard shaped like a rectangle and attach it to the sword to make the second part of the hilt. Fasten the piece of cardboard to the sword with duct tape and colour as desired.


Even though the sword is fake, do not put it anywhere near another person's body or face. Doing so could cause injury.

Tips and warnings

  • Even though the sword is fake, do not put it anywhere near another person's body or face. Doing so could cause injury.

Things you need

  • Cardboard
  • Scissors or razor blade
  • Duct tape or electrical tape
  • Pencil
  • ½ inch dowel rod
  • Aluminium foil
  • Clear packaging tape
  • Coloured markers or paints

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