Interested in doing your own blacksmithing? The best resource my inexperienced eye has seen can be found here. Like many online communities of people who do things were a lot of newcomers want to pick up hard won skills in an afternoon, they have a lot of problems with such people. Instead of getting sarcastic and cruel, they write articles on how to make complex master crafts like swords, liberally sprinkled with, "But you need years of practice, and some very cheap labor to make one of these, and no, we won't take you on as an apprentice..."

The short answer on how to make a sword? Buy some aircraft aluminum and make something that looks like a real steel people poker, but please don't -- the world doesn't need anymore swords, really.