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Sword Art Online
How to make the sheath of Elucidator (with templates)
*How to make sword body section is here


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

[Main materials]
-EVA foam
→2mm or 1.5mm thick 100cm X 30cm
→3mm thick 100cm X 10cm
→5mm thick 100cm X 40cm
-White Synthetic leather 100cm X 10cm
-Black Synthetic leather 100cm X 20cm
-"Bond G17"(one of liqud glue in Japan) 200ml
-Liquid super glue 4pieces
-Hot melt(glue gun) 10pieces
-Velcro 10cm
-Rivet 2pieces

[Painting materials]
1.When a undercoat is Gesso
-Gesso 50ml
-lacquer paint(Bottle lacquer paint, Lacquer Spray etc) 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) 50ml
-lacquer thinner 50ml
-Paintbrush 1piece
-Paper cup, bowl etc 1piece
-lacquer paint(Bottle lacquer paint, Lacquer Spray etc) proper quantity*

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

Materials cost to make the sheath
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
-Paint tools, such as a paintbrush
-Tool set required for rivet

Convenient tools when you have
-Art knife PRO
-Gas toach
-Heat gun
-Super glue Accelerator

Work time to make the sheath
8hours

Spec
-Sword
Weight 150g
Length 100cm

-Sheath and belt
Weight 150g
Length 80cm

Template data
PDF format(A4 size)1/2 Sword,Sheath PDF format(A4 size)2/2 belt
-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.

1/2 Completion drawing


2/2 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.


Tutorial video
When you watch this video before reading this page, you can understand this page better.


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



How to build
Cut material into the Templates form.
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.

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

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【5mm厚COSボードをキャラヌノで買う】


【COSボードを楽天で買う】

-------------------------------------------------------------------------------------------------------
【5mm厚コスプレボードをAmazonで買う】


【コスプレボードを楽天で買う】

-------------------------------------------------------------------------------------------------------

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

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.

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

Bend by heating with a Gas toach or a Lighter or a Heat gun.
(When the area is large, using Gas toach is easier.)


←ガス充填式ライターとガスボンベを使うとお得


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.

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

I finished glueing.


Cut material into the Templates form.
Cut out 5mm thick EVA foam.
Cut out 2mm or 1.5mm thick EVA foam.
Glue with a Liquid super glue.

-------------------------------------------------------------------------------------------------------
【1.5mm厚COSボードをキャラヌノで買う】


【COSボードを楽天で買う】

-------------------------------------------------------------------------------------------------------
【1.5mm厚コスプレボードをAmazonで買う】


【コスプレボードを楽天で買う】

-------------------------------------------------------------------------------------------------------

Glue with a Liquid super glue.


I finished glueing.


Glue with a Liquid super glue.


Cut material into the Templates form.
Cut out 2mm or 1.5mm thick EVA foam.
Glue with a Liquid super glue.


Cut 2mm or 1.5mm thick EVA foam thin.


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)


Make rivets with a Hot melt(glue gun).



Glue Velcro with a Hot melt(glue gun).



Glue Velcro with a Hot melt(glue gun).


Glue Velcro with a Hot melt(glue gun).


I finished glueing.


Present state.


Cut material into the Templates form.
Cut out 5mm thick EVA foam.


Make holes on the Templates. Mark them with a pen.


I finished marking.


Cut material into the Templates form.
Cut out 3mm thick EVA foam.

-------------------------------------------------------------------------------------------------------
【3mm厚COSボードをキャラヌノで買う】


【COSボードを楽天で買う】

-------------------------------------------------------------------------------------------------------
【3mm厚コスプレボードをAmazonで買う】


【コスプレボードを楽天で買う】

-------------------------------------------------------------------------------------------------------

Glue with a Liquid super glue.


I finished glueing.


Cut 2mm or 1.5mm thick EVA foam thin.


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)


Glue Synthetic leather on the backside with a "Bond G17"(one of liqud glue in Japan) for reinforcement. Detailed process is here.
Don't use fire until drying, because "Bond G17" burns easily. Don' use a Lighter etc until drying.

PUストレッチレザー 生地 無地 全52色 黄 オレンジ 赤 ピンク 青系 17色布幅130cm 50cm以上10cm単位販売 価格：176円（税込、送料別) (2019/1/23時点)

ソフトエナメル 生地 無地 42色 モノトーン、ゴールド・シルバー系 全42色 布幅130cm 50cm以上10cm単位販売 価格：188円（税込、送料別) (2019/1/23時点)

I finished glueing.


How to paint
Stick Masking tape on the point you don't want to paint.



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 "Zoukei be-su" as undercoat this time.
However it's sold only in Japan.
Use Gesso or Thinned "Bond G17"(one of liqud glue in Japan) in substitution for "Zoukei be-su".


Paint "Zoukei be-su" twice with a brush.
Dry it about 2 ~ 6 hours.


Dry it about 2 ~ 6 hours.


Paint black with Lacquer Spray.


Paint black with Lacquer Spray.


Paint silver Bottle lacquer paint by Drybrush painting.


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.


Paint silver Bottle lacquer paint by Drybrush painting.


After painting
Cut material into the Templates form.
Cut out 2mm or 1.5mm thick EVA foam.
Glue Synthetic leather with "Bond G17"(one of liqud glue in Japan). Details are here.
Don't use fire until drying, because "Bond G17" burns easily. Don' use a Lighter etc until drying.


I finished glueing.


Cut out white Synthetic leather.


Glue with a Liquid super glue.


Glue with a Hot melt(glue gun).


I finished glueing.


Make hole with a Punch.

←手で押しこむだけでお手軽なタイプ←ハンマーで叩くタイプ

Attach Rivet with a striking stick. Details are here.


Attach Rivet with a striking stick. Details are here.


Glue Velcro with "Bond G17"(one of liqud glue in Japan). Detailes are here.
Don't use fire until drying, because "Bond G17" burns easily. Don' use a Lighter etc until drying.



I finished glueing.


Sew Velcro with a sewing machine.


Make a hole with a Box cutter.


Attach the sheath with Velcro.


I finished attaching.


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