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How to make Kitchen knife (with templates)


Materials
[Materials for making pattern paper]
-"Kousakuyousi"(one of hard paper in Japan) 1piece

[Main materials]
-EVA foam
10mm thick 100cm X 10cm
-"Kousakuyousi"(one of hard paper in Japan)1piece
-"Bond G17"(one of liqud glue in Japan) 10ml
-Liquid instant glue 1piece
-Hot melt(glue gun) 10piece(It's convenient if there is also Air duster for cooling))
-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*

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*
-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
-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
2Hours

Spec
Weight 20g
Length 30cm

Pattern paper data
PDF format(A4 size) or JPG format

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-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 EVA foam.

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 Templates from "Kousakuyousi"(one of hard paper in Japan).



Make a blade.
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 a sharp blade. For example, "Pro Blade".
This is so sharp.
10 50肨pbN

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.

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


Cutting was completed.


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.


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



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.


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.


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


Pasting ws caompleted.


Make grip.
Copy the edges of Templates on a material with a pen.
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
Cutting was completed.


Dig a ditch with a Box cutter.


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


Paste one more. 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.)

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


Form by shaving 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)

KX[UC^[ƃKX{xgƂ

Toasting was completed.


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.

yMeritz
-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.

yDemeritz
-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.

yRecommendationz
-Weapons
-Armors without a moving part.

yUndercoatz
Gesso or Black Gesso
or

yPaintz
Lacquer Spray or Bottle lacquer paint or acrylic paint
or
-------------------------------------------------------------------------------------------
2.Thinned "Bond G17"(one of liqud glue in Japan)
This is difficult.

yMeritz
-It's sold in D.I.Y shops.
-It'st hard to peel off.
-It can use for PVC pipe or plastic sheets.

yDemeritz
-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.)

yRecommendationz
-All props
(Props with a moving part in particular)

yUndercoatz
"Bond G17"(one of liqud glue in Japan) thined with lacquer thinner
-for big things -for small things

yPaintz
Lacquer Spray or Bottle lacquer paint

-------------------------------------------------------------------------------------------
I use Gesso in this tutorial.
Paint Gesso twice or three times with a brush.


Dry it about 2 ~ 6 hours.


Paint black color with Lacquer Spray.


Paint Bottle lacquer paint by Drybrush painting.
(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.


Painting was completed.


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


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