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



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

[Main materials]
-EVA foam
→2mm or 1.5mm thick 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(When you use a Air duster for cooling, it's convenient))
-Aluminum stick 1piece
-cord 3m
-Snap 2pieces

[Painting materials]
1.When a undercoat is Gesso
-Gesso 50ml
-lacquer paint(Bottle lacquer paint, Lacquer Spray etc) or acrylic paint proper quantity*
-Lacquer Spray proper quantity*
-Masking tape 1piece

2.When a undercoat is Thinned "Bond G17"(one of liqud glue in Japan)
-"Bond G17"(one of liqud glue in Japan) 100ml
-lacquer thinner 100ml
-Paintbrush 1piece
-Paper cup, bowl etc 1piece
-lacquer paint(Bottle lacquer paint, Lacquer Spray etc) proper quantity*
-Masking tape 1piece

*The paiting area is written in the package, refer it. Details are here.

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

Tools
-Writing implement(Pencil,eraser,ballpoint,Magic Marker,ruler)
-Scissors
-Box cutter(Use also a "Pro blade" and a "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
-Tools for processing plastic sheets(sandpaper etc)

Convenient tools when you have
-Art knife PRO
-Instant glue Accelerator
This spary can harden Instant glue instantly. Details are here.
←100ml ←180ml ←420ml

Work time
20Hours

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

Template
PDF format(A4 size) or JPG format

When you use templates, please subscribe my youtube channel.
Click this↓ And Click "subscribe".

-If you print on browser, it may not be full scale. 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, When you print it by magnification 100%, it will be full scale.
-After printing, it becomes easy to use by sticking it on Drawing paper with spray glue.
-Mentions of "x1","x2" etc are the numbers of sheets.
(If you need both arms or both legs etc, cut the number of double.)
-Mentions of "2mm" , "5mm" etc are thickness of EVA foam.

Attention in the work
-When you uses a thing including the thinner(Bond, lacquer thinner etc) or spray, make good ventilation.
And wear a gas mask.
<-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.

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

-Don't use fire near the things which are easy to burn such as paint, thinner etc.

-When you finished using tools, pull an outlet.

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

How to make
Make Templates from "Kousakuyousi"(one of hard paper in Japan).



Make blade.
Make a strong material by glueing "Kousakuyousi"(one of hard paper in Japan) and Plastic sheets.
Put "Kousakuyousi"(one of hard paper in Japan) side by side.
Glue 0.5mm thick Plastic sheets with "Bond G17"(one of liqud glue in Japan) while straddling borderlines of "Kousakuyousi"(one of hard paper in Japan).
Don't use fire until drying, because "Bond G17" burns easily. Don' use a Lighter etc until drying.
After this, the plastic side is used as the face, the paper side is used as the back.



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


Use Aluminum stick as a core.
You can use a Wood stick, a plastic stick, a Gardening stick made by glass fiber instead of it.
(If you worry about strength, insert Gardening stick made by glass fiber the inside of Aluminum stick.Details are here.)
Cut it into appropriate length with a Pliers.


Glue the Aluminum stick.
Glue with a Hot melt(glue gun).



Glue another blade.
Glue with a Hot melt(glue gun).


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


Filling was completed.


Stroke the back of blade with a tip of Hot melt(glue gun), then the surface becomes flat.


Glue the edge of blade.
Glue with a Liquid instant glue.
When you use a Instant glue Accelerator, Hardening speed becomes fast.
(Smoke may be generated. Don't breathe in the smoke and don't put in eyes.)


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


Instant glue can glue a large surfaces easily.
But it can't glue a small surface such as this photo well


Then you should use a following spray.
I always use this.
Watch movie.

Instant glue Accelerator
This can glue surfaces in several seconds.
When you use 100ml, you can make a armorset or about three weapons.
←100ml ←180ml ←420ml

About instant glue
I use general liquid Instant glue.


Case of sticking except instant glue.
"Bond G17"(one of liqud glue in Japan) can glue too. It's can glue narrow surfaces too.
But it's take time.
Moreover, when you use Thinned "Bond G17"(one of liqud glue in Japan) as a undercoat,
glued surfaces may melt.
(If you use Gesso, there is no problem.)

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


Glueing was completed.


Paint silver with Lacquer Spray.


Paint black with Lacquer Spray.


Actually, I used a Airbrush.
If you want to make light and shade, use it.
About Airbrush is here.

←初心者にもオススメのセット、私も愛用してます。

Make grip.
Cut out 5mm thick EVA foam.
Cut out 2mm or 1.5mm thick EVA foam.


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

EVA foam is a soft material.
You can process it easily.
Another name is EVA board, EVA zote, Craft foam etc.
I usually use one called "Lion board".
"Lion board" is sold only in Japan.

Watch video.

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


【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。
私もこの商品を使っています。


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】


【5mm厚COSボードを楽天で買う】


【5mm厚COSボードをネット通販で買う】


【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。
私もこの商品を使っています。


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】


【1.5mm厚COSボードを楽天で買う】


【1.5mm厚COSボードをネット通販で買う】


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

Use a sharp blade. For example, "Pro Blade".
This is so sharp.
←10枚入り ←50枚入りお得パック

When you cut, put EVA foam 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.

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


Glue with a Liquid instant glue.


Mark pattern by penn.
Cut out with a Box cutter.


Glue with a Liquid instant glue.


Make guard.
Cut out 5mm thick EVA foam.
Cut out 2mm or 1.5mm thick EVA foam.
Glue with a Liquid instant glue.


Mark pattern by penn.


Marking was completed.


Dig marked pattern with a Soldering iron.(Don't breathe in the smoke and don't put in eyes)



Make a hole with a Box cutter.


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


Remove the corner by toasting with a Lighter.(Don't breathe in the smoke and don't put in eyes)

←ガス充填式ライターとガスボンベを使うとお得

Paint a undercoat on EVA foam.
The effects are as follows.

-Color becomes well.
-It becomes hard to come off.
-Gloss comes out well.
-You can save quantity of the paint.

There are two methods.
-------------------------------------------------------------------------------------------
1.Gesso
This is easy.

【Merit】
-It's usable just to paint with a paint brush.
-Gesso don't contain thinner, then you can use it in the room.
-You can use also Acrylic paint.

【Demerit】
-It's easy to come off than Thinned "Bond G17"(one of liqud glue in Japan). (Moving parts in particular)
-It can't use for PVC pipe or plastic sheets.

【Recommendation】
-Weapons
-Armors without a moving part.

【Undercoat】
Gesso or Black Gesso
or

【Paint】
Lacquer Spray or Bottle lacquer paint or acrylic paint
or
-------------------------------------------------------------------------------------------
2.Thinned "Bond G17"(one of liqud glue in Japan)
This is difficult.

【Merit】
-It's sold in D.I.Y shops.
-It'st hard to peel off.
-It can use for PVC pipe or plastic sheets.

【Demerit】
-You must thin it.
-It needs thinner, then you must work outdoors.
-It burns easily.
Don't use fire until drying, because "Bond G17" burns easily. Don' use a Lighter etc until drying.
The parts will be charred in seconds.

【Recommendation】
-All props
(Props with a moving part in particular)

【Tutorial video】


【Undercoat】
"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

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

I use Thinned "Bond G17"(one of liqud glue in Japan) in this tutorial.
But I recommend Gesso for begginers.


Paint "Bond G17"(one of liqud glue in Japan) thined with lacquer thinner three or four times.
Don't use fire until drying, because "Bond G17" burns easily. Don' use a Lighter etc until drying.
(It will char in seconds.)
Dry it about 2 ~ 6 hours.


Paint black with Lacquer Spray.


Stick Masking tape on the point you don't want to paint.



Paint gold with Lacquer Spray.


Peel Masking tape softly.


Paint gold of Bottle lacquer paint with a paint brush.


When you paint Bottle lacquer paint, use a paintbrush,silicon cup(Use as a paint plate. It can easy to peel paints after dry.),
panint stick, thinner.


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


Cut end of grip. Cut with a Box cutter.


Melt a Hot melt(glue gun) by heating with a Electric stove.



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


Paste end of grip. Glue with a 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.



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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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