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How to make Sabre (with templates)

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

[Main materials]
-EVA foam
→2mm or 1.5mm thick 100cm X 10cm
→5mm thick 100cm X 30cm
→10mm thick 100cm X 20cm
-"Kousakuyousi"(one of hard paper in Japan)2piece
-Liquid super glue 3piece
-Hot melt(glue gun) 10piece(1piece is cleare color)(When you use a Air duster for cooling, it's convenient))
-Aluminum stick 1piece

[Painting materials]
1.When a undercoat is Gesso
-Gesso 50ml
-lacquer paint(Bottle lacquer paint, Lacquer Spray etc) or acrylic paint 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
1000Yen (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
-Paint tools, such as a paintbrush
-Pliers

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

Work time
7Hours

Spec
Weight 100g
Length 90cm

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.

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



Make 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).
(If you want to more strong blade, use also Plastic sheets. Details are here.)


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 several Aluminum stick cut short on the bending points.



Pile joints of sticks a little for improving strength.
(Surrounded part by red circle)


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


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.


Swelling became flat.


Glue edges of the blade.
Glue with "Bond G17"(one of liqud glue in Japan).
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.



Glue with a Liquid super glue.


Glueing was completed.
Paste Liquid super glue to edge of blade.


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


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


Filling was completed.


Make guard.
Make Templates from "Kousakuyousi"(one of hard paper in Japan).
Copy the edges of Templates on a material with a pen.
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)】
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。


楽天なら


【5mm厚COSボード】


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

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 grip.
Make Templates from "Kousakuyousi"(one of hard paper in Japan).
Copy the edges of Templates on a material with a pen.
Cut out 10mm thick EVA foam.


【10mm厚ライオンボード(別名:リアラボード)】
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。


楽天なら


【10mm厚COSボード】


Dig a ditch with a Box cutter.


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.

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


Shave the corner with a Box cutter.


Mark pattern by penn.


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



Digging was completed.


Glue with a Hot melt(glue gun).


Glueing was completed.


Make grip guard.
Make Templates from Drawing paper.
When you want to know detailed tutorial of making Templates, browse this page.



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


Assemble the fair copy.
When you make a ideal from, cut open it. Use it.


Copy the edges of Templates on a material with a pen.
Cut out 5mm thick EVA foam.


Glue with a Liquid super glue.


Reinforce by heaping a Hot melt(glue gun) on the backside of glueing places.
Glue Cloth or Synthetic leather on points with burdens.


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

←ガス充填式ライターとガスボンベを使うとお得

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


Swelling became flat.


Glue with a Liquid super glue.


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


Toasting was completed.


Make rivets with a Hot melt(glue gun).


Cut 2mm or 1.5mm thick EVA foam thin.


【1.5mm厚ライオンボード(別名:リアラボード)】
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。


楽天なら


【1.5mm厚COSボード】


Paste together parts cut out from 2mm or 1.5mm thick EVA foam with a Liquid super glue.


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 Gesso in this tutorial.


Paint Gesso twice or three times 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.


Drybrush paint gold with Bottle lacquer paint with a paint brush.


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


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.


Painting was completed.


Paint red color of Bottle lacquer paint with a paint brush.


Serve with Clear color Hot melt(glue gun).


Paint clear blue color of Bottle lacquer paint with a paint brush.


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