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How to make Nunchaku


Materials
[Materials for making pattern paper]
-

[Main materials]
-"Lion Board(Koyo Soft Board)"
→2mm thick(1.5mm is also OK) 100cm X 30cm
→5mm thick 100cm X 10cm
-"Kousakuyousi"(one of hard paper in Japan)4piece
-"Bond G17"(one of liqud glue in Japan) 100ml
-Liquid instant glue 1piece
-Hot melt(glue gun) 10piece(It's convenient if there is also Air duster for cooling))
-PVC pipe(diameter 26.0mm) 1piece
-Chain 1piece

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

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)
-Freeway coping saw
-Paint tools, such as a paintbrush

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
4Hours

Spec
Weight 250g
All Length 110cm
Length of Stick 1 piece 40cm

Pattern paper data
I threw away the Pattern paper, so It's can't upload.

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 a stick part.
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.



Cutting was completed.


Polish with sand paper(240 grid) for sticking bond well.
(If you don't polish, it can be adhered. The polished one sticks more easy.)



Cut out 2mm(1.5mm is also OK) 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.
*******************************************************************************************


【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。
私がライオンボードを使う場合はリアラボードという商品名の物を使用しています。
こちらは通常&特大サイズ。お買い得な複数枚セット商品も有り。


ハーフサイズ。お買い得な複数枚セット商品も有り。


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)を楽天で買うなら】


【1.5mm厚COSボードをネット通販で買う】


【1.5mm厚COSボードを楽天市場で買う】


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

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.

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


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 5mm thick "Lion Board(Koyo Soft Board)".


【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。
私がライオンボードを使う場合はリアラボードという商品名の物を使用しています。
こちらは通常&特大サイズ。お買い得な複数枚セット商品も有り。


ハーフサイズ。お買い得な複数枚セット商品も有り。


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)を楽天で買うなら】


【5mm厚COSボードをネット通販で買う】


【5mm厚COSボードを楽天市場で買う】



Paste together with Liquid instant glue.


Mark pattern by penn.


Dig pattern marked with Soldering iron.(Don't breathe smoke,don't let smoke meets eyes)



Write pattern with Hot melt(glue gun).



Writing was completed.


Cut chain proper length.
Plastic chain can be cut with Pliers.
Cutting metaric cahin need big wire cutter etc,
so you have metaric chain is cut by shop.


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.)


Stick Masking tape so that paint may not adhere to unrelated place.



Paint black color as undercoat 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.



Youtube video and completed photos
I uploaded video version of this tutorial.
Please watch this too.








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