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How to make Big blade sabre


Materials
[Materials for making pattern paper]
-"Kousakuyousi"(one of hard paper in Japan) 5piece
-Scotch tape(Sellotape) 3piece
-Packaging tape(parcel tape) 1piece

[Main materials]
-EVA foam
→10mm thick 100cm X 10cm
-"Kousakuyousi"(one of hard paper in Japan) 4piece
-Synthetic leather 100cm X 20cm
-Liquid instant glue 3piece
-Hot melt(glue gun) 10piece (It's convenient if there is also Air duster for cooling)
-"Jiyujizai"(one of wire in Japan)
→6mm 150cm

[Painting materials]
1.When a undercoat is Gesso
-Gesso 100ml
-lacquer paint(Bottle lacquer paint,Lacquer Spray) 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) 200ml
-lacquer thinner 200ml
-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
2500Yen (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
-Paint tools, such as a paintbrush
-Pliers

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
15Hours

Spec
-

Templates
I threw away the Templates, so It's can't upload.

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
Cut "Kousakuyousi"(one of hard paper in Japan) into a belt form.
Put "Kousakuyousi"(one of hard paper in Japan) side by side.
Glue them with a Hot melt(glue gun) and the belt.



Cut out "Kousakuyousi"(one of hard paper in Japan).


Use 6mm thick "Jiyujizai"(one of wire in Japan) as core.
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).


Glue edges of the blade.
Glue with "Bond G17"(one of liqud glue in Japan).
(If you want to more strong blade, use also Plastic sheets. Details are here.)



Paste Liquid instant glue to edge of blade.


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


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.)

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


Cut EVA foam to width of back. Glue with a Hot melt(glue gun).


Make guard.
Cut out 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】


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

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 Hot melt(glue gun).


Make end of grip.
Cut out 10mm thick EVA foam.


【10mm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。


【10mm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】


【10mm厚COSボードをネット通販で買う】


【10mm厚COSボードを楽天市場で買う】


Glue with a Hot melt(glue gun).
Draw patterns with a Hot melt(glue gun).


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.
(It will char in seconds.)

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

【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 color as undercoat color with Lacquer Spray.


Paint 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.


Cut Synthetic leather to shape of a strip of paper.




Paste "Jiyujizai"(one of wire in Japan). Glue with a Hot melt(glue gun).


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