Roronoa Zoro's sword he got in Loguetown, Yubashiri.

After so long it's finally done. I started working on this sword along with Wado Ichimonji and Sandai Kitetsu back at the end of August. I could have finished earlier but I got real lazy and procrastinated big time. The sword itself was made of poplar and the sheath finger joint pine(with some craft plywood here and there). Also if you notice, the edge has some detailing to it, which I used silver enamel model paint to achieve.

Now for the details:

Handle- The endcap details and the ring going around the handle were done with paperclay. The button is just simply some wooden buttons I bought at Canadian Tire and glued onto the handle.

Tsuba- The fine details are a combination of craft plywood and paperclay. The inner border was made with the plywood and filed to make it bevelled. I ran into a few problems with the wood snapping while shaping. The 'D' shapes were made using paperclay. My original plan was to use the plywood for everything but realized it would be too much of a pain to cut and to shape.

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. I originally started using a dremel to hollow it out but I found I was getting more done just using a chisel. I ended up nailing myself in the thumb with the chisel and cutting it pretty bad. Word of advice; be real careful when chiseling and get some leather gloves just in case(I hit my hands a few times after getting the gloves and they protected them). After chiseling and lining with fabric I glued the 2 pieces together, planed and then rounded the sheath using a palm sander with 50 grit sandpaper. The fine details were all done with paperclay

Zoro's Other Swords:
Sandai Kitetsu [link]
Wado Ichimonji [link]