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How to make Chinese sword (with templates)


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

[Main materials]
-EVA foam
→2mm or 1.5mm thick 100cm X 10cm
→5mm thick 100cm X 10cm
→10mm thick 100cm X 30cm
-"Kousakuyousi"(one of hard paper in Japan) 2sheets
-Plastic sheets 0.5mm thick 2sheets
-"Bond G17"(one of liqud glue in Japan) 100ml
-Liquid instant glue 2pieces
-"Black instant glue(one of instant glue in Japan) 1piece
-Hot melt(glue gun) 10pieces (When you use a Air duster for cooling, it's convenient)
-Aluminum stick 1piece
-Iron gardening stick 1piece
-Gardening stick made by glass fiber 1piece

[Painting materials]
-Natural sand 100ml
-lacquer paint(Bottle lacquer paint,Lacquer Spray) proper quantity*
-Surface Primer 1piece

Below are standart method.
1.When a undercoat is Gesso
-Gesso 50ml
-lacquer paint(Bottle lacquer paint, Lacquer Spray etc) or acrylic paint proper quantity*
-Surface Primer 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(Disposable premise ) 1piece
-Paper cup,bowl etc.(Disposable premise ) 1piece
-lacquer paint(Bottle lacquer paint, Lacquer Spray etc) proper quantity*
-Surface Primer 1piece

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

Materials cost
3000Yen (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
-Saw
-Paint tools, such as a paintbrush
-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
25hours

Spec
Weight 230g
Length 90cm

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).
When you want to know detailed tutorial of making Templates, browse this page.


Make the 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.


Make a strong core by combining a Gardening stick made by glass fiber and a Aluminum stick.
Cut it into appropriate length with a Pliers.


Use Gardening stick made by glass fiber as core.
Cut a Gardening stick made by glass fiber into appropriate length.
When you use a Fret saw or a Freeway coping saw, you can cut it easily and neatly.
You can cut also Pliers, nippers, diamond files.



In some cases, adjust the thickness by peeling the skin of Gardening stick made by glass fiber with a Box cutter.
Paint "Bond G17"(one of liqud glue in Japan) on it, and insert to the Aluminum stick.
Don't use fire until drying, because "Bond G17" burns easily. Don' use a Lighter etc until drying.



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



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


Glueing was completed.


Fill the back with EVA foam.
Cut out 10mm 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.

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


【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。


【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】


【10mm厚COSボードを楽天で買う】


【10mm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.


Glueing was completed.


Paste 0.5mm thick Plastic sheets.
Glue with a Liquid instant glue.


Cut protruded parts.


Cutting was completed.


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.


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


Heap "Black instant glue(one of instant glue in Japan) on cracks and flaws.



Polish heaped points with about 120 ~ 400 grit sand paper.


Spray Surface Primer.
Cracks and hollows stand out after drying.
If there are cracks and hollows yet, repeat heaping and polishing.
When the surface becomes flat, begin paintig.



Paint gunmetal color with Lacquer Spray.


Draw patterns in blade.
Paint silver 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。

Painting was completed.


Paint gloss spray to make a gloss.



Make the grip guard.
Copy the edges of Templates on a material with a pen.
Cut out 10mm thick EVA foam.


Glue with a Liquid instant glue.


Glue with a Liquid instant glue.


Form by shaving 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

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


【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】


Form by shaving with a Box cutter.


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


Glue with a Liquid instant glue.


Draw patterns with a Hot melt(glue gun).


Make the grip.
Copy the edges of Templates on a material with a pen.
Cut out 2mm or 1.5mm thick EVA foam.
Cut out 10mm thick EVA foam.


【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】


Glue with a Liquid instant glue.


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.



Bend a Iron gardening stick by striking softly with a hammer.


Crush Iron gardening stick lightly for prevention falling out when blade inserted.


Glue with a Hot melt(glue gun).


Glue with a Liquid instant glue.


Shave the corner with a Box cutter.


Shaving was completed.


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


Glue with a Liquid instant glue.


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


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 usually use the methods mentioned above.
In this time, I paint Natural sand for making a scabrous surface.
Natural sand is one of undercoat for acrylic paint.
It's made in Liquitex Co.



Paint Natural sand twice with a brush.
Dry it about 2 ~ 6 hours.


Dry it about 2 ~ 6 hours.


Paint gray color as undercoat color with Lacquer Spray.


Paint navy blue color with Lacquer Spray.


Drybrush paint color mixed blue and white Bottle lacquer paint with a paint brush.
(Drybrush painting is easy, you can do it with a paint brush. Details are here.)


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 gold of Bottle lacquer paint with a paint brush.


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Dismantle state.


How to aasemble.


Complete.


Visitor's works
御伽クロさん
【リルカ様武器完成】
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!
柄の素材はコスファクさんのコスプレボードで下地は造形ベース。
実は剣を作るの初めてw


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