Anybody make their own? I've been trying to excuse to my wife why I bought some cheap "Japanese" swords (made in Taiwan, R.O.C.). If I could make one of 'em usable in my routine, she might let me keep the rest.

Sammy the Kid

If you are talking about the card sword ie: impaling a card on the tip of a sword then you are probably out of luck. The card swords that sell for 250+ dollars are not infact swords at all, but more like long pointed tubes of metal. I can't say much more without divulging any secrets. however in some of the older books there are sleight of hand methods of accomplishing this effect with an ungimmicked sword. Most rely on some heavy misdirection and are not nearly as clean as the manufactured effect. Happy hunting and the best of luck.