Here's how to make your own from fabric
www.angelfire.com/realm2/al...cover.html

www.anomaly.org/wade/padde...cCover.html

from duct tape
www.instructables.com/id/Duct...-sheath/

to buy them
www.karatekorner.com/index.c...0059.htm

www.martialartsmart.net/Cases_...es.html

www.sakuramartialarts.com/Marti...43.htm

or just go to any martial art store online

*giggle*...I had to check out the duct tape method...my son makes all kinds of stuff out of duct tape and my daughter loves making bracelets out of the coloured variety. Kids!

Anyhow...I'd suggest using light cardboard and covering it with cloth. Just place the sword on top of the piece of cardboard and cut it slightly larger than the blade. After you have your two pieces, take strips of fabric and wrap it evenly around it. I'd say go over it twice to completely cover it. Once it's covered, sew the loose ends and that way, if you want to glue embellishments onto it, you've got a pretty background cover. You can make a strap out of the same fabric or use a braided cord and you're in sheath bliss! :-D

Just my suggestion.

a couple of dancers from AODC use old rifle cases.. picked up from family, friends,good will etc...