Cardboard Gargantuan Sword of Death and DestructionThe safest, most versatile and inexpensive way to make a costume sword is by way of foam or cardboard. Both can be easily obtained and are lightweight, but cardboard is easier to cut-out, layer with multiple designs and color with spray paint. A cardboard sword can become as over-the-top or simplistic as you want at barely any cost or time.

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, The Art of the Halloween Costume Cardboard Sword,
–Via Makezine