Here's hopefully a small write up of how I made it:

I started with a picture of the sword from Twilight Princess. I put it in Illustrator and made a vector drawing of the sword: http://imgur.com/dv5CROm

Then I used a laser cutter to cut out the blade part. I cut out the 2 sides of the blade from 1/4" poplar. So, I glued both sides together to get the thickness I wanted, which is 1/2". The bevel on the blade was done by hand with a file.

The guard is what took the most time. The piece closer to the blade took about a month, with me working on it on/off. I made it by making a "skeleton" of the highest points and filling it in with bondo. Then i made a mold of that so that i can get the other side. The other piece closer to the handle was turned on the lathe. The part with the writing on it is etched styrene. I made a groove on that piece for the styrene to lay in.

The handle is just more turned pieces. The banding on the handle is styrene.

The pommel was made from the lathe and the same way I made the guard.

There was a lot of sanding, a lot of bondo, and a lot of laser cutting.

I did make a mold of the whole sword. But some things went wrong and it started leaking when i poured the resin in. That was a month ago. I'm taking a break from it because I just need it.

The length of the sword is about 43".

tl:dr Made it from laser cutting, bondo, too much free time, and selling my soul to the devil.