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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]
-Drawing paper 10sheets
-"Kousakuyousi"(one of hard paper in Japan) 5sheets
-Scotch tape(Sellotape) 1piece
-Packaging tape(parcel tape) 1piece

[Main materials]
-EVA foam
→2mm or 1.5mm thick 100cm X 10cm
→3mm thick 100cm X 10cm
→5mm thick 100cm X 10cm
-"Kousakuyousi"(one of hard paper in Japan) 4sheets
-"Bond G17"(one of liqud glue in Japan) 100ml
-Liquid super glue 3pieces
-Hot melt(glue gun) 10pieces (When you use a Air duster for cooling, it's convenient)
-Iron gardening stick 1piece
-cord 3m

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

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*

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

Materials cost
1500Yen (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
-Paint tools, such as a paintbrush
-Electric stove

Convenient tools when you have
-Art knife PRO
-Super glue Accelerator

Work time
5hours

Spec
-Katana
Weight 180g
Length 100cm

-Sheath
Weight 80g
Length 80cm

Template data
PDF format(A4 size)

-How to print is here.
-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.

Completion drawing


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.


-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.


Tutorial video
When you watch this video before reading this page, you can understand this page better.


How to make
Make Templates from Drawing paper and "Kousakuyousi"(one of hard paper in Japan).
When you want to know detailed tutorial of making Templates, browse this page.




Make the blade.
Cut "Kousakuyousi"(one of hard paper in Japan) into a belt form.


Put "Kousakuyousi"(one of hard paper in Japan) side by side.


Glue the belt with a Hot melt(glue gun).



Copy the edges of Templates on a material with a pen.
Cut out "Kousakuyousi"(one of hard paper in Japan).


Use Iron gardening stick as core.
Cut it.
When you use a Freeway coping saw, you can cut it easily and neatly.
You can cut also Pliers, nippers, diamond files.



I used this in this time.


Peel with a Box cutter to easily bend.


Bend Iron gardening stick by hand.


Glue with a Hot melt(glue gun).



Glueing was completed.


Glue with a Hot melt(glue gun).


Glueing was completed.


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


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


Glue edges of the blade.
Glue with "Bond G17"(one of liqud glue in Japan). Detailed process is here.
Paint it with a broken piece of "Kousakuyousi"(one of hard paper in Japan) as a brush.
Don't use fire until drying, because "Bond G17" burns easily. Don' use a Lighter etc until drying.



Glueing wea completed.


Reinforce the blade by painting Liquid super glue on the edge.


Copy the edges of Templates on a material with a pen.
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.

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


-------------------------------------------------------------------------------------------------------
【1.5mm厚COSボード】


【1.5mm厚ライオンボード(別名:リアラボード)】


楽天なら


【コスプレボード】
楽天なら


Amazonならこちら
-------------------------------------------------------------------------------------------------------

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

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 super glue.
When you use a Super glue Accelerator, Hardening speed becomes fast.
(Smoke may be generated. Don't breathe in the smoke and don't put in eyes.)


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


Super 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 video.


Super 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 super glue
I use general liquid super glue.

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


Make the guard and grip.
Copy the edges of Templates on a material with a pen.
Cut out 5mm thick EVA foam.
Cut out 2mm or 1.5mm thick EVA foam.
Glue with a Liquid super glue.

-------------------------------------------------------------------------------------------------------
【5mm厚COSボード】


【5mm厚ライオンボード(別名:リアラボード)】


楽天なら


【コスプレボード】
楽天なら


Amazonならこちら
-------------------------------------------------------------------------------------------------------

Glueing was completed.


Make a hole with a Box cutter.


Glue with a Liquid super glue.


Glueing was completed.


Copy the edges of Templates on a material with a pen.
Cut out 3mm thick EVA foam.

-------------------------------------------------------------------------------------------------------
【3mm厚COSボード】


【3mm厚ライオンボード(別名:リアラボード)】


楽天なら


【コスプレボード】
楽天なら


Amazonならこちら
-------------------------------------------------------------------------------------------------------

Glue with a Liquid super glue.


Glue with a Liquid super glue.


Glueing was completed.


Glue with a Hot melt(glue gun).


Glueing was completed.


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.


Copy the edges of Templates on a material with a pen.
Cut out 2mm or 1.5mm thick EVA foam.


Glueing was completed.


Cut out 2mm or 1.5mm thick EVA foam.
Glue with a Liquid super glue.


Cut unnecessary points with a Box cutter.


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

Draw patterns with a Hot melt(glue gun).


Present state.


Begin painting.
At first, 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.
-There are several colors one, white black etc.

【Demerit】
-It's easy to come off than Thinned "Bond G17"(one of liqud glue in Japan).
 Then, use this for weapons and armors without moving parts.
-The gross is smaller than Thinned "Bond G17"(one of liqud glue in Japan).

【Commodities page】
Gesso or Black Gesso
or

【Paint】
Lacquer Spray or Bottle lacquer paint or acrylic paint
or
-------------------------------------------------------------------------------------------
2."Bond G17"(one of liqud glue in Japan)
This is difficult, however it's almighty.

【Merit】
-It'st hard to peel off.
-It can use for PVC pipe or plastic sheets.

【Demerit】
-"Bond G17" is japanese commodity.
 Then you can't get it easily.
 Please use others. For example, you can substitute wood glue for it.
-You must thin it with lacquer thinner.
-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.

【Tutorial video】


【Commodities page】
"Bond G17"(one of liqud glue in Japan) thined with lacquer thinner
-for big things -for small things
-------------------------------------------------------------------------------------------
-About paint
I use following paint.


You can use acrylic paint, when you use Gesso.

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

I use "Zoukei be-su" as undercoat this time.
However it's sold only in Japan.
Use Gesso or Thinned "Bond G17"(one of liqud glue in Japan) in substitution for "Zoukei be-su".


Paint "Zoukei be-su" twice with a brush.
Dry it about 2 ~ 6 hours.


Paint black color as undercoat color with Lacquer Spray.


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



Paint silver with Lacquer Spray.


Reproduce The design of the edge.
Paint Bottle lacquer paint with a Airbrush.

←初心者にもオススメのセット、私も愛用してます。

Paint gloss spray to make a gloss.



Paint gold 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.


Paint silver Bottle lacquer paint by Drybrush painting.


Drybrush painting is easy, you can do it with a paint brush.
Read here or watch this video.


Paint silver Bottle lacquer paint by Drybrush painting.


Put the center of 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. Glue the end with Hot melt(glue gun).


Completed.


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れんげさん
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