Find a pattern *

Print the pattern (once it's the correct size) *

Cur the foam to the pattern *

Glue the core to the center foam piece *

The hard thin plastic serves 2 functions: adds rigidity, prevents the core from escaping (with use) *

Glue the foam together *

Cut off the excess core, trim and tape the handle. *

Trim the blade. (A bandsaw with an adjustable table works nicely.) *

Pin the cloth cover into place. *

Sew the cover. (Inside curves need to be sew by hand.) *

Hand sewn seems can be folded over and glued down. (The pins are removed after the glue dries.) *

Add a cross guard (optional) *

Latex any exposed foam. *