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How to make Broad sword (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 100cm
-Synthetic leather 100cm X 20cm
-"Bond G17"(one of liqud glue in Japan) 100ml
-Liquid instant glue 5pieces
-Hot melt(glue gun) 10piece(It's convenient if there is also Air duster for cooling))
-Aluminum stick 1piece
-PVC pipe(diameter 26.0mm) 1piece

[Painting materials]
1.Case of Gesso painting
-Gesso 50ml
-lacquer paint(Bottle lacquer paint, Lacquer Spray etc) or acrylic paint proper quantity*

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*

*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
-Saw(Pipe cutter is also OK)
-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
6Hours

Spec
Weight 150g
Length 110cm

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 blade.
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)".


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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.
*******************************************************************************************


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【5mm厚】通常&特大サイズ - 基本のサイズ、複数枚セットで買うとさらにお得


【5mm厚】ハーフサイズ-少しだけ使いたい場合にオススメ


【5mm厚】シール付き-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


楽天で購入するなら

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

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.

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


Cutting out was completed.


Center is Mark by penn.


Dig ditch with Box cutter.


Digging was completed.


Mark end to 5mm position. Mark by penn.


Cut at 45 degrees matching mak. Cut with Box cutter.


Cutting was completed.


Paste Aluminum stick with Hot melt(glue gun).



Pasting was completed.


Serve to other blade's ditch of blade with Hot melt(glue gun).


Pasting was completed. (In this time, don't paste except ditch.)


Paste part of except dtich. 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.

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


Pasting was completed.


Cut out 2mm(1.5mm is also OK) thick "Lion Board(Koyo Soft Board)".

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【1.5mm厚】通常&特大サイズ - 基本のサイズ、複数枚セットで買うとさらにお得


【1.5mm厚】ハーフサイズ-少しだけ使いたい場合にオススメ


【1.5mm厚】シール付き-裏面がシールになってて接着剤使わず貼り付け可能、装飾等にオススメ


楽天で購入するなら

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Paste with Liquid instant glue.


Make guard.
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.


Shave corner with Box cutter.


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


Paste with Hot melt(glue gun).


Pasting was completed.


Make grip.
Use PVC pipe(diameter 26.0mm).
Cut PVC pipe. PVC pipe can be cut by saw. But Pipe cutter is more bettr.Pipe cutter can cat quickly and beautifull.



Paste Synthetic leather with "Bond G17"(one of liqud glue in Japan). Concrete procedure is here.
Don't use fire after painting until drying, because "Bond G17"burns easily. Don' use Lighter etc until drying.



Pasting was completed.


Serve Hot melt(glue gun) to inside of PVC pipe.
Cover PVC pipe to Aluminum stick come out from blade.


Serve Hot melt(glue gun) to inside of PVC pipe.


Make grip end.
Cut out 5mm thick "Lion Board(Koyo Soft Board)".
Tools are needed to cut out beautiful circle form.Details are here.)



Paste together with Liquid instant glue.


Paste with Hot melt(glue gun).


Pasting was completed.


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.
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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
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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

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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 with Lacquer Spray.


Drybrush paint 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.



I uploaded movie version of this tutorial.
If you feel this tutorial good, please push "good button" of below movie.










Visitor's works
天使リリィさん
こちらは真・三國無双7の孫権のDLC武器 焔刃剣です。
ブロードソードの作り方など、色々参考にさせていただきました。
刀身に穴がいくつか空いているので、苦戦しましたが支柱を3本入れてなんとか形を維持することができました。
ドライブラシも初めてやってみました


mikiさん
今回の防具、武器ともにギャクヨガ様参考にさせていただきました。
この方なんでも作っちゃうんだもん。説明丁寧ですし。拝んじゃお。ありがとうございました。


ミツトさん
初めまして。いつも参考にさせていたたいております!
先日レイピアやブロードソードを元に、SAOのアスナのランベントライトを作りました。
少し出来はあれですが、参考にさせていただきありがとうございました!


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