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Greenzaku
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My group mostly stuck to 3rd weapons as they appear the most often in official art. I'm still new to making props myself (I was able to manage Kenshin's weapon because its fairly wide and sturdy, so I could make it almost purely out of compressed foam) But Ranmaru's weapon is longer and thinner; so making it out of foam would be very fragile.

You might need access to power tools to make the blade...I dunno if the workshop will help you with that. Otherwise there is a tutorial here:

http://sgcafe.com/showthread.php?t=51842

The tutorial only seems to cover a straight sword however, so you will need to obtain a curved piece of wood to work with at the start, and modify the design since Ranmaru's weapon has some jaggedness. If you get some light, foam clay from Daiso, you can use it to smooth out irregular parts and sculpt on small details too. Then everything can be painted with spray or acrylic paints.

For the handle, if you go to youtube and type in 'how to wrap a katana handle' you'll get some nice instructional vids.
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