Overview#
After completing the Master Sword for my son, my daughter requested her own Legend of Zelda weapon for Halloween. She specifically wanted the Savage Lynel Sword from Breath of the Wild - a formidable, brutal-looking blade wielded by one of the game's most challenging enemies.
This project was a bit more complex than the Master Sword, incorporating not just cardboard but also metal bolt heads and plastic chain to better match the game's aesthetic. Despite the added complexity, I still managed to complete it in a single weekend, just in time for Halloween festivities.
Materials Used#
- Corrugated cardboard (5 layers for this sword, more than the Master Sword)
- Flat wooden dowel for the central spine
- Metal bolt heads for decoration
- Plastic chain (painted silver)
- PVC wood glue for edge hardening
- Spray paint (metallic silver/chrome, red, gold/tan)
- Masking tape for sectioning during painting
- Basic craft tools (utility knife, scissors, ruler)
Creating the Template#
For this sword, I used a slightly different approach to creating the template. Instead of digital tracing, I used grid paper to manually scale up the design. I drew a grid over a reference image from the game, then recreated it at larger scale on grid paper.
While this method worked, I'd definitely recommend the digital approach I outlined in the Master Sword post . Creating templates digitally gives you more precision and flexibility to make adjustments before cutting.
The Building Process#
Layered Cardboard Construction#
Unlike the Master Sword which used 3 layers of cardboard, the Savage Lynel Sword required 5 layers to achieve the proper thickness and strength. This sword has a more substantial appearance in the game, and I wanted to capture that bulkier feel.
As with the Master Sword, I cut each layer with the corrugation running in alternating directions for maximum strength. With 5 layers, this sword ended up extremely rigid and durable. The flat wooden dowel running through the center provided additional support, preventing any flexing during use.
Painting and Detailing#
The Savage Lynel Sword has a distinctive color scheme with a silver/chrome blade, red handle, and gold/tan crossguard and pommel. Using simple and cheap hardware rattle cans, som painters tape and a few rounds of painting you can get some decent results. It's no master piece, but fine for our purposes.
The cardboard takes the spray paint easily, so no need for any priming or base coat. I then:
- Masked off the handles and top of the blade area to apply the chrome edging
- Using the original paper template, I then masked out the chrome edge and applied the charcoal blade top layer
- Painting some of the guard and overlaid elements, either masked or seperately as needed
The contrast between the metallic blade and the colored handle sections created a striking appearance that closely matched the game item.
Adding the Finishing Touches#
What makes the Savage Lynel Sword unique is its rough, primitive appearance with metal elements. To capture this look, I incorporated:
- Metal bolt heads placed strategically along the blade and hilt to mimic the rough, hammered look of the game version
- Plastic chain wrapped around the handle and connecting to the pommel, painted silver to match the metallic aesthetic
These small additions made a huge difference in the final appearance, elevating it beyond a simple cardboard creation to something that looked much more like the in-game weapon.
The Finished Sword#
The completed Savage Lynel Sword turned out to be an impressive companion to the Master Sword. While not perfect replicas, together they created an unmistakable Legend of Zelda theme for the kids' Halloween costumes.
Despite being built in a rush over a single weekend, the sword has proven surprisingly durable. The 5-layer construction and alternating corrugation pattern created a rigid structure that has withstood plenty of enthusiastic play.
Halloween Debut#
The real test came on Halloween night when both kids got to show off their Legend of Zelda weapons. The combination of the Master Sword and Savage Lynel Sword made for a striking pair of props that were instantly recognizable to fellow Zelda fans.
Final Thoughts#
Creating the Savage Lynel Sword in a single weekend demonstrated just how quickly you can produce impressive props with simple materials when you have the right techniques. The combination of this sword with the Master Sword created a perfect Zelda-themed Halloween for the kids.
While I didn't preserve the template for this project, the techniques used are the same as those outlined in my other sword builds. For more Zelda and sword-related projects that grow in complexity beyond these, take a look at the Swords-n-Stuff series.