I have seen places that sell fire tools sometimes also sell extra wicking...i would imagine drilling (gasp) holes into your sword (gasp) using appopriate thread to stitch on the wicking, and viola...you have a sword with wicking on it.

then again, that's just my guess, i haven't ever done it.....

Hey,
My amigo Hjeron made some fire swords a few years back (and maybe more since then, I don't know offhand). He might have some advice.... and from what I recall, I think he wrapped either wire or kevlar thread or both over top of the wicking that was wrapped around the sword.
You should be able to find him through his tribe group, you could probably ask him directly what he did: tribes.tribe.net/mythmaker

Also, check out Fire by Riz (sorry I can't recall the website address, but you should be able to find it by googling the name)--- he makes fire swords for sale -- but there may be descriptions of materials he uses?

Riz's site is www.firewhip.com/ (I've seen him come along the tribes too)

Some sites with info are (as I have not worked with fire - yet - I cannot vouch for any of them):
www.luxotica.com/education.../sword.cfm
lostbiro.com/blog/
tribes.tribe.net/fireartse...69c1d0903f

I've made a couple pairs of them.

The first one was simply an iron bar I got at a farm supply place. I drilled 3/8" holes and wove Kevlar rope through the holes. It didn't work too well until I wove a second rope through it so I had enough kevlar to hold fire for a while.

For the second set, I happened across some very cheap, like $25 each, short Chinese broad swords. I drilled much smaller holes, using up several drill bits because it was very difficult to drill. I put three strands of kevlar rope along the back side and used stainless steel wire to attach the rope.

But I don't put them on my head. For that I'd probably only do the last six inches or so. You pretty much need to drill holes, and when I do my next set, I'm thinking I may go to a machine shop and have them do the drilling -- they have better equipment for that. The reason for the holes is to insure that the kevlar will stay in place. You don't want flaming things flying off when you sweep the blade around.

I've also worked with a Katana that a friend turned into a fire sword by folding 2" wide kevlar over the back side and securing it with only two holes, using a nut and bolt to hold it in place.