For shaping, a file set with a rasp can to just about everything, some of the tighter spots can be more difficult, but I used files for most everything here, also sandpaper, namely 220 and 400 grit. A dremel is also amazing if you can get one. As for cutting, A coping saw and a hack saw are great. Here's a good tutorial on here I found a couple years back that uses just hand tools, [link]
For mine I made it 30" in the blade and about 10" in the handle. I sized it for myself since I'm so short (5'5"), so I tell everyone that asks me that if they're a bit taller, spring for maybe 45"-50" overall. Generally a longsword style sword of that length looks kinda silly for someone who's around 6'.
I've been asked by a few people, and a much a I'd love to, I don't really have the time or resources to make many of these by hand. As for maybe molding and casting them, I'm concerned about the legality of it.
Loving this. I was searching for reference for making this sword and i stumble upon this. Making it from lite material so it can be (Con-safe) =[ Anime Boston lol. At the Moment im planning on using Balsa Wood/Styrofoam/Clay. But this... THIS. Amazing Can't wait to see your future Tutorial.
Thanks! Good luck with yours, the tutorial might take a bit, I've been really busy lately. And i plan on bringing mine to a con, It depends on the con but most are fine as long as it's not metal or overly sharp.