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How to make Sabre (with pattern)

Materials
[Materials for making pattern paper]
-"Kousakuyousi"(one of hard paper in Japan) 5piece

[Main materials]
-"Lion Board(Koyo Soft Board)"
→2mm thick(1.5mm is also OK) 100cm X 10cm
→5mm thick 100cm X 30cm
→10mm thick 100cm X 20cm
-"Kousakuyousi"(one of hard paper in Japan)2piece
-Liquid instant glue 3piece
-Hot melt(glue gun) 10piece(1piece is cleare color)(It's convenient if there is also Air duster for cooling))
-Aluminum stick 1piece

[Painting materials]
1.Case of Gesso painting
-Gesso 50ml
-lacquer paint(Bottle lacquer paint, Lacquer Spray etc) or acrylic paint 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
1000Yen (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
-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
7Hours

Spec
Weight 100g
Length 90cm

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.
Paste "Kousakuyousi"(one of hard paper in Japan) cut beltlike by Hot melt(glue gun).
Some "Kousakuyousi"(one of hard paper in Japan) ties to one sheet.



Copy the edges of Pattern paper on a material with a pen.
Cut out "Kousakuyousi"(one of hard paper in Japan).
If you worry blade is "Kousakuyousi"(one of hard paper in Japan), use Plastic sheets too. Details are here.


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.)


Cut Aluminum stick to length with a sufficient degree with pliers.


Paste Aluminum stick with Hot melt(glue gun).
Paste Aluminum stick cut short to bending position.



Pile up Joint of Aluminum stick and Aluminum stick 2 or 3cm.(Surrounded part by red circle)
If you don't pile up, intensity decrease very much.


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


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


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


Pressing was completed.


Paste edge of blade with "Bond G17"(one of liqud glue in Japan).
Using broken piece of "Kousakuyousi"(one of hard paper in Japan) as brush is convenience.
Don't use fire after painting until drying, because "Bond G17"burns easily. Don' use Lighter etc until drying.



Pasting.


Pasting was completed.
Paste Liquid instant glue to edge of blade.


Paste Aluminum stick with Hot melt(glue gun).


Fill up gap. Fill up with Hot melt(glue gun).


Filling was completed.


Make guard.
Make Pattern paper by "Kousakuyousi"(one of hard paper in Japan).
Copy the edges of Pattern paper on a material with a pen.
Cut out 5mm 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】


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

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 with Hot melt(glue gun).


Make grip.
Make Pattern paper by "Kousakuyousi"(one of hard paper in Japan).
Copy the edges of Pattern paper on a material with a pen.
Cut out 10mm thick "Lion Board(Koyo Soft Board)".


【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】


Dig ditch with Box cutter.


Paste together 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.

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


Shave corner with Box cutter.


Mark pattern by penn.


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



Digging was completed.


Paste with Hot melt(glue gun).


Pasting was completed.


Make grip guard.
Make Pattern paper by Drawing paper.
When you want to know how to make fundamental Pattern paper,watch this page.



Cut open.
Copy to new Drawing paper and make a fair copy.


Assemble fair copy again.
When you make ideal form, it's cut open.Let it be formal Pattern paper.


Copy the edges of Pattern paper on a material with a pen.
Cut out 5mm thick "Lion Board(Koyo Soft Board)".


Paste together with Liquid instant glue.


Serve Hot melt(glue gun) as reinforce to backside of place pasting together "Lion Board(Koyo Soft Board)".
Paste Cloth or Synthetic leather to the end of stressful place with Hot melt(glue gun), and futhermore reinforce.


Heat swelling with Lighter, and press by finger.Swelling will be plain.

←ガス充填式ライターとガスボンベを使うとお得

Pressing.


Pressing was completed.


Paste with Liquid instant glue.


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


Toasting was completed.


Make like a rivet with Hot melt(glue gun).


Make thing cutting 2mm(1.5mm is also OK) thick "Lion Board(Koyo Soft Board)" small.


【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】


Paste together parts cut out from 2mm(1.5mm is also OK) thick "Lion Board(Koyo Soft Board)" with a Liquid instant glue.


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 Gesso painting.


Paint Gesso twice or three times with brush.
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 as undercoat color with Lacquer Spray.


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



Paint silver color with Lacquer Spray.


Drybrush paint gold color with Bottle lacquer paint with paintbrush.
(You can Drybrush paint easy with blush. Details are here.)


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.


Painting was completed.


Paint red color of Bottle lacquer paint with paintbrush.


Serve with Clear color Hot melt(glue gun).


Paint clear blue color of Bottle lacquer paint with paintbrush.


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












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子供が持つので、刃もライオンボードで作ってあります。持ち手に血糊が染みています。


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