If you have a power (belt)sander that will really reduce the time needed to make the sword.
I have used a wood rasp and then sanded by hand, but that takes some time and elbow grease!
Home Depot or Lowes has a good selection of Poplar and Maple wood. I would suggest buying that type of wood, as the grain is really small, which means after you paint you can't tell it's wood. The 1/2" thick pieces look the best, IMO.
Post pics when you complete it! I would love to see what other people do with the rusting technique.
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