Roronoa Zoro's other sword he got in Loguetown, Sandai Kitetsu.

This sword was easier to make than Yubashiri but harder than Wado Ichimonji. The sword itself was made of poplar and the sheath pine.

Now for the details:

Handle- The endcap details and the middle part were of the handle were done with paperclay. Before wrapping the handle I thought it would be super easy but it's harder than it looks to get it right.

Tsuba- The embossed details were made with craft plywood. For the lower part of it I used a dremel with a carving piece to get it that way and then lots of wood filler after.

Sheath- The sheath was made out of 2 pieces of wood hollowed out using a chisel and then lined with a thin suede fabric called I think parké. After gluing the sheath together I planed it then rounded the edges off using a palm sander with 50 grit sandpaper. As for the grooves in the sheath, I wouldn't have been able to do it without a dremel. For that I used a cutting wheel bit. After that I used paperclay for the endcap. There are a few screwups in the paint job since this wash rushed a bit. I also glossed too much in some spots. In the near future I would like to repaint it.

Zoro's Other Swords:
Yubashiri [link]
Wado Ichimonji [link]