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Location: Orlando, Florida
Always a cool thing to make toys for kids. If they know it's hand-made, it might pique their interest in the hobby. Two pieces is the way to go. Were it me, I'd round off the sharp points. If the kid is as active and wild as I was as a kid, there's bound to be some blood drawn somewhere.
Still Learning,
Allan Hill
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id make the blade, guard, and grip one piece( a blank) the thickness of the blade then laminate guard and grip on.
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Dowel, glue.
I would use a single 1/4" dowel.
I would "sharpen" the sword blade to the last 1" near the blade guard leaving a thicker bolster for the dowel to enter. I doubt that you would have room for two dowels, but if you do, then use both.
I think a wood dowel will be strong enough, but alternatively, you can use a steel rod with epoxy.
No animals were injured or killed in the production of this post.
