[TheForge] Shortcut Sword?

[Ed F]

Not to discourage my Son and make him question what good all this
metalworking gear is, I agreed to make him a sword.

At this point I have no interest in making a sword so I'd like to do
something quick but decent.  Fortunately he's 7 so it won't have to be big.

I'm thinking of cutting the profile from a 1/4" leaf-spring and then somehow
getting the edges beat down with the 50# little giant, then taking a bull
grinder and finally the sander to the mess.  Maybe I'll pound the whole
thing thin before cutting to make it lighter.

For heat treat I thought I'd maybe just heat it up to red and let it air
cool.  He won't be doing any heavy duty edge abuse (I hope).

I have never made a long flexible thing before and I don't know what to
expect from the leaf spring steel in that application.

Any suggestions?  (ideas for *easier* methods *most* welcome).

Thanks -
Ed