Answers:
Check out the Society for Creative Anachronism.
They have figured out how to make both realistic artifacts from history, and how to make mock ones that are safe to use. They have also learned a lot about safety in the handling of the artifacts, both realistic and mock.
For example, you are wearing a sword on a belt. You are at a convention & you bend over to examine something closely on some table. As you bend over, the sword on your belt goes through an arc, so it is pointed behind you and jabs someone.
You need to know how to wear it, how to move, so as to avoid such unintentional attacks on people standing around you.
An easy way to make one would be with cardboard. Just find a big cardboard box, draw out the shape of the sword and then cut it out. Then use tin foil to wrap around the "blade" part of the sword and use crayons, pencils or markers to color the handle.
Wow, I happen to know somebody who makes swords, but I don't have his particular contact info. probably just research it, but you have to be experienced in metalurgy. and it is good to know leather working to make the grip on the handle. This guy makes professional swords and he uses classical techniques (not manufactured processes). If you email me I may be able to get his contact, but it will take a few weeks.
Otherwise research metalurgy, sword making, etc...
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