Bill Doran of Punished Props knows how to create just about anything out of foam. He recently teamed up with Grace, a.k.a. cosplayer Zonbi, to make an orc sword, though you could obviously apply this how-to to any kind of sword. They started with a piece of paper in the rough shape of the sword and traced it onto about 10mm of EVA foam. The above video goes through the construction process, while the below video details how to paint the sword to look metallic.
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