I used to make wooden swords all the time, using a scroll saw to cut out the area in the middle of the cross guard for the blade to go through.
I also once made a sap, out of duct tape and split-shot sinkers. I also have a sjambok of sort, several layers of duct tape of a core of paper and staples. Hurts like heck to be hit with, and is a killer flyswatter.