TTF’s Instructable on making a cool Japanese boken – “Here I describe the method for making a boken, which is a Japanese wooden sword. The skill level required using this method is relatively low. A more challenging option would be to do this only using hand-tools. I suggest that you borrow or buy a boken before you start, so you can get the feel and see the details of what you are making. It will also help you set up the curvature of the one you create. Hopefully you are already training with one at some level, so you have an understanding of the balance it should have. Ganbate kudasai (Japanese for good luck).” Link.
HOW TO – Make a Japanese Boken