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Shin Sangoku Musou6(Dynasty Warrior6)
Kanpei's sword
How to make Big sword



Materials
[Materials for making templates]
-Drawing paper 10piece
-"Kousakuyousi"(one of hard paper in Japan) 10piece
-Scotch tape(Sellotape) 3piece
-Packaging tape(parcel tape) 1piece

[Main materials]
-EVA foam
→2mm or 1.5mm thick 100cm X 30cm
→5mm thick 100cm X 120cm
→10mm thick 100cm X 10cm
-"Kousakuyousi"(one of hard paper in Japan) 4piece
-Plastic sheets 0.5mm thick 4piece
-Liquid super glue 13piece
-"Black instant glue(one of instant glue in Japan) 1piece
-Polyester putty 100g
-Hot melt(glue gun) 20piece(When you use a Air duster for cooling, it's convenient))
-PVC pipe(diameter 32.0mm) 1piece
-Stick for jointing PVC pipe 25cm

[Painting materials]
1.When a undercoat is Gesso
-Gesso 250ml
-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) 500ml
-lacquer thinner 100ml
-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
7000Yen (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
-Soldering iron and soldering iron stand
-Saw or Pipe cutter
-Paint tools, such as a paintbrush
-Tools for processing plastic sheets(sandpaper etc)

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

Work time
60Hours

Spec
Weight 1.6kg
Length 180cm

Template data
I threw away the Templates, so I can't upload.

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.

How to make
Make Templates from Drawing paper and "Kousakuyousi"(one of hard paper in Japan).
When you want to know detailed tutorial of making Templates, browse this page.
This is a blade pate.





Make Templates from Drawing paper and "Kousakuyousi"(one of hard paper in Japan).
These are grip guard part and grip part.


Copy the edges of Templates on a material with a pen.
Cut out 5mm thick EVA foam.
Cut out 2mm or 1.5mm 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.

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


【5mm厚ライオンボード(別名:リアラボード)】
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。


楽天なら


【5mm厚COSボード】


【1.5mm厚ライオンボード(別名:リアラボード)】
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。


楽天なら


【1.5mm厚COSボード】


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

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.

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


Mark pattern with a pen and the Templates.


Make a core.
Use a PVC pipe(diameter 32.0mm).
Cut a PVC pipe.
PVC pipe can be cut with a saw.
But a Pipe cutter is more better.
It can cut quickly and neatly.



This is a video of cutting method of PVC pipe, bending method, jointing method.


When you use this, joint with a stick.


Make a stick.
The best length is 25cm.
There are two methods.
-------------------------------------------------------------------------------------------
1.Iron gardening stick and EVA foam
It's take time, however jointing power is strong.

Cut Iron gardening stick. How to cut is here.
Cut out 2mm or 1.5mm thick EVA foam.
Glue with a Liquid super glue.

-------------------------------------------------------------------------------------------
2.Wood stick
It's a easy method, but jointing power is weak than above method.

Cut a wood stick with a saw.
Shave it with Box cutter as necessary.

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

Check the joint part has no problem.
Hang materials of the blade.


It's OK If it don't occurs problems, when it was lifted up and swinged.


Cut out 10mm thick EVA foam.
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.)


【10mm厚ライオンボード(別名:リアラボード)】
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。


楽天なら


【10mm厚COSボード】


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


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.

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


Glue the PVC pipe.
Glue with a Hot melt(glue gun).



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


Copy the edges of Templates on a material with a pen.
Cut out 2mm or 1.5mm thick EVA foam.
Glue with a Liquid super glue.


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


Glue with a Liquid super glue.


Dig a pattern with a Soldering iron.(Don't breathe in the smoke and don't put in eyes)



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

Cut out 10mm thick EVA foam.
Glue with a Liquid super glue.


Make blade edge.
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.


Cutting.


Cutting was completed.


Temporal tack with Masking tape.



Glue with a Hot melt(glue gun).


Glue the edge of blade.
Glue with a Liquid super glue.


Glueing was completed.


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



Heap Polyester putty to cracks and flaws.

←120g ←1kg

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


トゲを作る。
Copy the edges of Templates on a material with a pen.
Cut out 2mm or 1.5mm thick EVA foam.


Glue with a Liquid super glue.
The edge breaks easily, then cut it.


Heap a Hot melt(glue gun) for reinforcement.


Glue with a Hot melt(glue gun).


Make a guard.
Copy the edges of Templates on a material with a pen.
Cut out 5mm thick EVA foam.
Cut out 2mm or 1.5mm thick EVA foam.


Mark pattern by penn.


Marking was completed.


Glue with a Liquid super glue.


Glue with a Liquid super glue.


Glue with a Liquid super glue.


Glue with a Liquid super glue.


Reinforce by heaping a Hot melt(glue gun) on the backside of glueing places.
Glue Cloth or Synthetic leather on points with burdens.


Heat with Gas toach and bend.
(A Lighter is usable, too But take time.)



←ガス充填式ライターとガスボンベを使うとお得

Cut out 2mm or 1.5mm thick EVA foam.
Glue with a Liquid super glue.


Make prickles.
Cut out 2mm or 1.5mm thick EVA foam.


Heap a Hot melt(glue gun) for reinforcement.


The edge breaks easily, then cut it.


Glue with a Hot melt(glue gun).


Cut out 10mm thick EVA foam.
Glue with a Liquid super glue.
You must use a tool for cutting out a fair circle. Details are here.



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 a ecclosure put the blade in.
Cut out 10mm thick EVA foam.
Glue with a Liquid super glue.


Glue with a Hot melt(glue gun).


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


Glue with a Liquid super glue.


Copy the edges of Templates on a material with a pen.
Cut out 5mm thick EVA foam.
A ball part is used with cleare plastick half ball.


Glue with a Liquid super glue.


Glue the PVC pipe.
Glue with a Liquid super glue.


Copy the edges of Templates on a material with a pen.
Cut out 2mm or 1.5mm thick EVA foam.
Mark pattern by penn.


Dig marked pattern with a Soldering iron.(Don't breathe in the smoke and don't put in eyes)


Glue with a Liquid super glue.


Copy the edges of Templates on a material with a pen.
Cut out 5mm thick EVA foam.
Cut out 2mm or 1.5mm thick EVA foam.


Glue with a Liquid super glue.
Draw patterns with a Hot melt(glue gun).


Glue with a Liquid super glue.


Make structure can be fitted to guard.
This is equipping state.



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 Thinned "Bond G17"(one of liqud glue in Japan) in this tutorial.
But I recommend Gesso for begginers.
*When you use Gesso, don't paint it on the plastic sheet part.


Paint "Bond G17"(one of liqud glue in Japan) thined with lacquer thinner three or four times.
Don't use fire until drying, because "Bond G17" burns easily. Don' use a Lighter etc until drying.
(It will char in seconds.)
Dry it about 2 ~ 6 hours.


Dry it about 2 ~ 6 hours.


Stand it with a wood struck big nails.


Paint black color as undercoat color with Lacquer Spray.


Paint gold 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 gold Bottle lacquer paint by Drybrush painting.


Paint gold Bottle lacquer paint by Drybrush painting.


Paint Bottle lacquer paint by Drybrush painting.


Paint cleare orange color of Bottle lacquer paint with a paint brush.


Paint Bottle lacquer paint by Drybrush painting.


Paint Bottle lacquer paint by Drybrush painting.


Paint Bottle lacquer paint by Drybrush painting.


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Dismantle state.


How to assemble. Insert grip upper to guard and joint.


Thrust the wood stick.


Joint girp and blade.


Complete.


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