How to Make a Trojan Sword Out of Cardboard

by Ruth O'Neil

Kids, and even some adults, like to have play sword fights. Because of the constant contact play swords get, they can wear out quickly. Using cardboard to make a Trojan sword is a good craft project for parents and kids. These swords are inexpensive to construct and make use of recycling. Make several swords at one time to give you spares. Use cardboard Trojan swords as party favors for boys' birthday parties, for props for school plays or at Halloween.

Items you will need

  • Refrigerator boxes
  • Pencil
  • Utility knife
  • Spray adhesive
  • Hot glue
  • Spray paint
  • Cording
  • Needle
Step 1

Cut the refrigerator box sides apart to make four separate pieces. Use at least two layers of the cardboard to make your swords. Use the pencil to draw out a Trojan-style sword.

Step 2

Cut out one layer of the sword using the utility knife, with adult supervision. Use the first sword cut-out to make one more layer of the cardboard. Compare the two pieces of sword cardboard to make sure they are exactly the same size. Use the knife to trim the cardboard if needed.

Step 3

Glue the two layers of cardboard sword together using spray adhesive.

Step 4

Use excess cardboard to make a decorative hilt. Make two pieces that you can glue to either side of the sword. A hilt can consist of circles or squares that have an emblem of your own design painted on it. Hot glue works best when attaching the hilt to the sword just above the handle.

Step 5

Spray the sword to give it proper sword color. Make sure to spray paint all sides of the sword, giving them more than one coat. Allow the sword to dry for about four hours, depending on the type of spray paint you use.

Step 6

Wrap the cording around the handle of the sword. This makes it much more comfortable to handle and gives it some decoration, such as a Trojan sword would have. Tape one end of the cording at the bottom of the handle, to hold the cording in place while you wrap.

Step 7

Continue wrapping the handle, working toward the top and then back down again, until the shape is round and fits nicely into the owner's hand. Trim the cording, leaving a 5-inch length of excess. Use a large needle to thread the excess down into the wrapped cording to hold all of the cording in place.

Tips & Warnings

  • When working with spray adhesives, use them outside or in a workshop. Spray adhesives can get on everything in the room, even the things you do not want, if you use them indoors.
  • If you can get your hands on thicker or sturdier cardboard, it will make swords that will last longer than the refrigerator boxes.
  • Using duct tape is another option when making your Trojan swords. Instead of painting the sword or using the cording, wrap the blade and the handle with different colors of duct tape.