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Sengoku Basara
Matsunaga Hisahide's katana
How to make katana (with pattern)
*How to make sheath section is here



Materials etc written in following is for making only katana body section.
Materials
[Materials for making pattern paper]
-"Kousakuyousi"(one of hard paper in Japan) 10piece
-Scotch tape(Sellotape) 3piece
-Packaging tape(parcel tape) 1piece

[Main materials]
-"Lion Board(Koyo Soft Board)"
→2mm thick(1.5mm is also OK) 100cm X 20cm
→5mm thick 100cm X 40cm
-"Kousakuyousi"(one of hard paper in Japan)4piece
-Plastic sheets 0.5mm thick 4piece
-Liquid instant glue 5pieces
-Hot melt(glue gun) 15piece(It's convenient if there is also Air duster for cooling))
-Aluminum stick 1piece
-cord 3m
-Snap 2pieces

[Painting materials]
1.Case of Gesso painting
-Gesso 50ml
-lacquer paint(Bottle lacquer paint, Lacquer Spray etc) or acrylic paint proper quantity*
-Lacquer Spray proper quantity*
-Masking tape 1piece

2.Case of "Bond G17" painting
-"Bond G17"(one of liqud glue in Japan) 100ml
-lacquer thinner 100ml
-Paintbrush(Disposable premise ) 1piece
-Paper cup,bowl etc.(Disposable premise ) 1piece
-lacquer paint(Bottle lacquer paint, Lacquer Spray etc) proper quantity*
-Masking tape 1piece

*Paiting are is written in the package, refer it. Detail is here.

Materials cost
2000Yen (about 100Yen = 1dollar)

Tools
-Writing implement(Pencil,eraser,ballpoint,Magic Marker,ruler)
-Sizzer
-Box cutter(It's good to change "Pro blade". Moreover,It will become convenient if there is also "Blade breaker")
-Cutting mat
-Hot melt(glue gun)
-Lighter
-Soldering iron and soldering iron stand
-Freeway coping saw
-Paint tools, such as a paintbrush
-Tool set required for snap
-Electric stove
-Things required for processing plastic sheets(sandpaper etc)

Convenience tools when you have
-Art knife PRO
-Instant glue Accelerator
This spary can harden Instant glue instantly.
It's so useful for glueing small part. Detail is here.
←100ml ←180ml ←420ml

Work time
20Hours

Spec
Weight 300g(Sheath=100g, Katana=150g)
Length 105cm

Pattern paper data
PDF format(A4 size) or JPG format

-It don't become full scale, if you print on browser. You should save the file on your PC, then print the file.
-In case of PDF format Use Adobe Reader(free ware)
-In case of JPG format it will become full scale, If it print by magnification 100%.
-It becomes easy to use by sticking it to Drawing paper with spray glue after printing.
-Grid in edge of pattern paper is standard that confirm about printing by magnification 100%.
-Mention called "x1","x2" etc are number of cutting pieces.
If you need both shoulder ,both legs etc,cut number of double.
-Mention called "2mm","5mm" etc are thick of "Lion Board(Koyo Soft Board)".

Attention at the time of work
Let's consider the following things for accident prevention and health.

-When it uses a thing including the thinner(Bond, lacquer thinner etc) and the spray, make good ventilation.
And wear a gas mask and .
<-I'm using this mask.

-When you toast mterials etc, make good ventilation.
And don't breathe smoke, don't put smoke in your eyes, wear a gas mask.

-When you dig mterials etc with Soldering iron, make good ventilation.
And don't breathe smoke, don't put smoke in your eyes, wear a gas mask.

-Do not use the lighter and tools with heart near the things which are easy to burn such as paint or thinner Bond.

-Turn off an outlet and the switch of the tool as soon as you have finished using it.

-Read labels of materials and tools carefully, and understand how to use.

How to make
Make Pattern paper by "Kousakuyousi"(one of hard paper in Japan).



Make blade.
Put "Kousakuyousi"(one of hard paper in Japan) side by side.
And paste 0.5mm thick Plastic sheets straddling borderline of "Kousakuyousi"(one of hard paper in Japan) with "Bond G17"(one of liqud glue in Japan).
Don't use fire after painting until drying, because "Bond G17"burns easily. Don' use Lighter etc until drying.
After this,side of Plastic sheets is used as face, side of "Kousakuyousi"(one of hard paper in Japan) is used as back.
(Reinforcement purpose.If it does not care about intensity,using only "Kousakuyousi"(one of hard paper in Japan) is OK.)



Copy the edges of Pattern paper on a material with a pen.
Cut out the glued board.


Use Aluminum stick as core.
(Wood stick, plastic stick,Gardening stick made by glass fiber are also OK.
If you worry about intensity, insert ,Gardening stick made by glass fiber to inside of Aluminum stick.
Details are here.)


Paste Aluminum stick with Hot melt(glue gun).



Paste one more blade with Hot melt(glue gun).


Fill the back of blade with Hot melt(glue gun).


Filling was completed.


Stroke the back of blade with tip of Hot melt(glue gun) and press.


Paste together edge of blade with Liquid instant glue.
Use Instant glue Accelerator to make good progress.
(In use, steam may be generated. But don't don't breath. And don't meet the steam in eyes.)


*******************************************************************************************

Instant glue can plane surface easy.
But it can't narrow surface well.
Then you should use bellow spray.
I always use this.
Watch movie.

For example, use bellow surface.


Instant glue Accelerator
This can stick surface in several seconds.
100ml can stick one armorset or about three weapons..
←100ml ←180ml ←420ml

About instant glue
General liquid Instant glue is OK.


Case of sticking except instant glue.
"Bond G17"(one of liqud glue in Japan) can stick too. It's can stick narrow surface too.
But it's take time more than Liquid instant glue and Instant glue Accelerator.
And "Bond G17"(one of liqud glue in Japan) may melt stuck surface if you use "Bond G17" painting.
(You should reinfore stuck surface with Liquid instant glue. Or use Gesso painting.)
After all Liquid instant glue and Instant glue Accelerator is the best.

*******************************************************************************************


Pasting was completed.


Paint silver color with Lacquer Spray.


Paint black color with Lacquer Spray.


Make grip.
Cut out 5mm thick "Lion Board(Koyo Soft Board)".
Cut out 2mm(1.5mm is also OK) thick "Lion Board(Koyo Soft Board)".


*******************************************************************************************

It's Japanese most famous material for cosplay props.
It's a soft board, and it can be bended.(Details are here.)
And "Lion Board(Koyo Soft Board)" is sold only in Japan.

Then, if you live in except japan, you must use other materials.
A EVA board is usable in substitution for "Lion Board(Koyo Soft Board)".
It's called EVA foam, EVAzote, too.
Many world cosplayers are using EVA board.
(I don't know well about EVA board, sorry. Plase study by Google)
Or, basicly soft and can bended board is substitutes.
Then find the materials in your country.

I don't know material information of except japan.
Then you must call for help to your country cosplayers, if you know more information of materials.
There are many world cosplayers in Worldcosplay.
Please find your contry cosplayer by this site. And ask them.
http://ja.worldcosplay.net/

Or, ask japanese material shops that the shop can send "Lion board" to your country.
Thease are shops selling "Lion board".
http://www.rakuten.ne.jp/gold/cosprop/ This site has Japanese page only.
http://www.tokyu-hands.co.jp/foreign.html This site has English page too.
*******************************************************************************************


【5mm厚ライオンボード(別名:リアラボード、ソフトボード)をAmazonで買う】
リアラボードという商品名ですがこれが俗に言うライオンボードです。
私がライオンボードを使う場合はリアラボードという商品名の物を使用しています。
こちらは通常&特大サイズ。お買い得な複数枚セット商品も有り。


ハーフサイズ。お買い得な複数枚セット商品も有り。


裏面がシールになってて接着剤を使わず貼り付け可能、装飾等にオススメ。


【5mm厚ライオンボード(別名:リアラボード、ソフトボード)を楽天で買うなら】


【5mm厚COSボードをネット通販で買う】


【5mm厚COSボードを楽天市場で買う】


【1.5mm厚ライオンボード(別名:リアラボード、ソフトボード)をAmazonで買う】
リアラボードという商品名ですがこれが俗に言うライオンボードです。
私がライオンボードを使う場合はリアラボードという商品名の物を使用しています。
こちらは通常&特大サイズ。お買い得な複数枚セット商品も有り。


ハーフサイズ。お買い得な複数枚セット商品も有り。


裏面がシールになってて接着剤を使わず貼り付け可能、装飾等にオススメ。


【1.5mm厚ライオンボード(別名:リアラボード、ソフトボード)を楽天で買うなら】


【1.5mm厚COSボードをネット通販で買う】


【1.5mm厚COSボードを楽天市場で買う】


*******************************************************************************************

At first, use sharp blade. For example, "Pro Blade".
This is so sharp.
In addition, use big size Box cutter.
Big size can cut well more than small size.
←10枚入り ←50枚入りお得パック

When you cut, put "Lion Board(Koyo Soft Board)" on Cutting mat.
Don't cut in the air, while holding by hand.
Break a b blade frequentry, if you feel sharpness of using blade became bad.
If you want to do work more speedy, use "Running fire box cutter","Blade breaker".
"Running fire box cutter" can have 6 pieces blade inside.
"Blade breaker" can break easy and speedy.


Use Art knife PRO for small ornaments etc.

*******************************************************************************************


Paste together with Liquid instant glue.


Mark pattern by penn.
Cut out with Box cutter.


Paste with Liquid instant glue.


Make guard.
Cut out 5mm thick "Lion Board(Koyo Soft Board)".
Cut out 2mm(1.5mm is also OK) thick "Lion Board(Koyo Soft Board)".
Paste together with Liquid instant glue.


Mark pattern by penn.


Marking was completed.


Dig pattern marked with Soldering iron.(Don't breathe smoke,don't let smoke meets eyes)



Make hole with Box cutter.


Paste grip. Paste with Hot melt(glue gun).


Toast with Lighter and remove corner.(Don't breathe smoke,don't let smoke meets eyes)

←ガス充填式ライターとガスボンベを使うとお得

Paint.
When you paint "Lion Board(Koyo Soft Board)", You can improve quality as follows
by painting the undercoat beforehand.

-Color becomes well.
-Painting becomes hard to come off.
-Gloss comes out well.(If you don't need gloss, you use no gloss paint.
-You can save quantity of the paint.

If you don't use undercoat, you can paint.
If you hope more quality, you sholud use it.

There are two undercoats mainly.
-------------------------------------------------------------------------------------------
1.Gesso painting (this is easy method) [Easy, for everybody]

Gesso don't contain thinner.Accordingly there is not smell worry.
It's only paintig by bruch, very easy.it can use Acrylic paint as paint.
This method is recommend for weapons, small articles, two or three pieces armors.
But it's easy to peel off than Gesso painting (this is easy method).
Then it's is slightly unsuitable for moving armor and armorset etc.

Details are here.

Undercort>>>Gesso or Black Gesso
or

Paint>>>Lacquer Spray or Bottle lacquer paint or acrylic paint
or
-------------------------------------------------------------------------------------------

-------------------------------------------------------------------------------------------
2."Bond G17" painting (this is hard method) [All-purpose,but hard. For a man used to making props]

It's fill thinner smell in room.Accordingly use outside of a room.
This is onerous method, but it's not hard to peel off. It's almighty method.
Then it's suitable for moving armor and armorset etc.
Don't use fire after painting until drying, because "Bond G17"burns easily. Don' use Lighter etc until drying.
The parts will be charred in seconds.
Details are here.

Undercort>>>"Bond G17"(one of liqud glue in Japan) thined with lacquer thinner
-for big things -for small things

Paint>>>Lacquer Spray or Bottle lacquer paint

-------------------------------------------------------------------------------------------

In subsequent explanation is use "Bond G17" painting.
But Gesso painting is easy to use.


Paint "Bond G17"(one of liqud glue in Japan) thined with lacquer thinner at 3 or 4 times.
Don't use fire after painting until drying, because "Bond G17"burns easily. Don' use Lighter etc until drying.
The parts will be charred in seconds.
Desiccate for 4 or 5 hours.(It may become dry for 1 or 2 hours, but Desiccating for 4 or 5 hours is better.)


Paint black color with Lacquer Spray.


Stick Masking tape so that paint may not adhere to unrelated place.



Paint gold color with Lacquer Spray.


Peel Masking tape softly.


Paint gold color of Bottle lacquer paint with paintbrush.


When paint Bottle lacquer paint, There should just be paintbrush,silicon cup(Use as paint plate. Easy to peel after dry.),
mixing colors stick,thinner.


Insert blade to grip. Paste with Hot melt(glue gun).


Cut end of grip. Cut with Box cutter.


Heat Hot melt(glue gun) with Electric stove and melt.



Pour melted Hot melt(glue gun) in inside of grip.
Hot melt(glue gun) get cold, then fix.
(You think why it pour from guard. Beacouse hole of guard is small,
then pouring is hard.)


Paste end of grip. Paste with Hot melt(glue gun).


Reel grip cord.
Grip cord is flat cord. Length is about 3m, width is about 1cm.
In addition, It's good using cord has no expansion and contraction.


Put center cord on upper part of grip.


Invert.


Twist left side cord to inside twice.


Twist right side cord to inside twice. Put on left side cord.
Be aware of making "X".


Invert.Twist left side cord to inside twice.


Twist right side cord to inside twice. Put on left side cord.


Repeat above process. When cord reachss end of grip, paste with Hot melt(glue gun).
Complete.



Youtube video and completed photos
I uploaded video version of this tutorial.
Please watch this too.














Visitor's works
れんげさん
明石国行、完成(^^*)
刃と鞘はギャクヨガさんのサイトの型紙を使用させていただきました!!
次回はちゃんとした材料と時間をかけて製作したいと思います!!


ともくんさん
コス始まってからお礼を忘れてました! 三連投になりますが報告します!
ギャクヨガ様の作例を参考にドリフターズ・島津豊久の野太刀と大太刀を製作しました!
原作イメージ重視でかなり大きくなっておりますw





カギアケさん
ギャクヨガさんのサイトを参考に…加州さんの得物。所々不細工ではあるけど、
それなりに雰囲気出てればいいかなーって。そこが限界。今年のニコニコ超会議に持っていく…間に合って良かった。




乱雲さん
【コス】先日の撮影で使用したにっかり青江はギャクヨガさんのサイトを参考に作成致しました。
刀がよく見える写真を選択




のりじさん
日本刀作った。家紋と鍔は手描き。かっこよかろ?
今回もギャクヨガさんのサイトを参考にさせて頂きました。







蜻蛉さん Twitter
ギャクヨガさんのサイトを参考に骨喰藤四郎鍛刀しました!
刃の部分は光沢の異なる紙テープ使用〜


刃の部分はこちらのテープを使いました。


土盛 ゆふぁさん
夏休みの美術の自由制作!!
鞘はもっかい塗り直してコスの小道具に使うのだ(≧∇≦)
ギャクヨガ様のサイトを参考にさせて頂きました!ありがとうございます!


心愛ママさん
先日、サイトにあった刀の柄の紐の巻き方を参考にして、
娘が歴史イベントに出場する時に使う模造刀の柄をやってみました。
ありがとうございました(*^_^*)


晴輝さん
ギャクヨガさんのサイトを参考にいろいろ試してやっと一兄の刀が完成(*´∀`)
刀の刀身部分は、木にアルミテープを巻いた作りになっているので少し作りが違いますので注意ください( *´艸`)




浅葱さん
鳴狐本体、一応作ってみた
遠目で撮ってもらおう
作り方はギャクヨガさんのサイトを参考にしました


ゴマちんさん
短期集中で半分程作り直せた…
なんとか渡せるであろう鶴丸国永になりました!
ギャクヨガさん本当にありがとうございました。゚(/□\*)゚。


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