/cgl/ - Cosplay & EGL

So I'm planning on going as Finn for Halloween and I already have blue jean shorts and a blue shirt so I'm going to be making Finn's hat, backpack and sword from scratch and I would appreciate your guy's help.
I'm going to be using this tutorial for the hat:
http://www.youtube.com/watch?v=NdoPbruiZgg
I'm wondering how I would print out this template http://archives.frederatorblogs.com/adventure_time/files/2010/03/finn-hat.pdf used in the video cause I only have a normal printer that prints on standard size paper.
Also I'm not sure if I should use this backpack tutorial:
http://www.youtube.com/watch?v=warRGUCzhuY&feature=fvwp&NR=1
or this one
http://www.youtube.com/watch?v=EzJJPuauq_A&feature=related
For the sword I want to make the demon sword (as seen in pic) since Finn will be a popular halloween costume and most people will use the golden sword http://images3.wikia.nocookie.net/__cb20120912043521/adventuretimewithfinnandjake/images/f/f6/Fu.png and I wanna have my costume stand out in some way. I couldn't find any good tutorials on making the Demon sword online and If anyone knows any good ones I would appreciate it.
I found this tutorial on making the golden sword that I could use as a last resort but I would preferably go with the Demon sword or something else, maybe even the multi-dimenshional sword http://images1.wikia.nocookie.net/__cb20110411103060/adventuretimewithfinnandjake/images/a/a3/4dmnss
word.jpg but that may be difficult.
[media]http://www.youtube.com/watch?v=lk8ULOroiQU[/media]
If you guys have any other tips or experience making this costume or alternatives tutorials or ways on how to make the costume a little different since so many people are going to be going as finn (robot arm finn, giant hero finn etc (budget is like 30 bucks max but keep in mind that I already have a lot of the materials needed.) etc that you would like to share I'm all http://i.imgur.com/PE3pR.jpg?9606