3 feet long is a big sword even made of plastic. You could try taking two thin pieces of soft wood as long as the blade + about an inch or so and as wide as the blade + an inch or so, and tracing the blade on them and then using a router to hollow out the blade shape on both sides. Then glue them together, make two belt loops out of a cheap leather belt and screw those to the backside, and paint the scabbard to suit. I did this for several of my swords that did not come with scabbards. (Except I was using treated oak and real leather.) Or, go to Wal-Mart and pick up a yard or so of thick vinyl material. This has the look and feel (somewhat) of leather. Trace the blade (+ an inch all around) onto the vinyl and make a front and rear section. Sew them together and sew on vinyl belt loops. Use the rest of the vinyl to fashion a belt, by folding a long rectangle three times longways and sewing it together. Fold over one end and sew on a steel ring about 2 inches in diameter (avail
able at Lowes or Home Depot). When putting on the belt, pass the free end thru the ring and then under the belt from the bottom so that the free end comes up pointing at your chin. Take it back down thru the loop thus formed and pull it tight on itself. If done correctly the free end will now be pointing straight down.
Hope this helps!
I had this problem for the last three years. I dressed as Frodo, the next year my son dressed as frodo and last year he dressed as a kknight. We had swords everytime and I could not find a belt or sheath. So I made one.
e-mail me if you want directions, fairly easy and not too expensive. Held up well, four years later we still use it.
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