To make Inuyasha’s Tessaiga sword, we sandwiched a dowel rod between two layers of pink insulation foam, using liquid nails to adhere them, and let it dry overnight.
Define the sword's edge by using an electric sander, or in my case, a drill with a sanding attachment. Important: Always wear a dust mask whenever sanding foam!
Once the foam has been shaped to your liking, give it three coats of gesso to fill in any minor nicks and prepare it for spray-paint.
Once the gesso has dried, spray paint the sword silver, hot glue faux fur around the base and wrap the hilt with black nylon ribbon (both materials found at Joann Fabric).