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Shin Sangoku Musou6(Dynasty Warrior6)
Kanpei's sword 2
How to make Big sword



Materials
[Materials for making templates]
-Drawing paper 10sheets
-"Kousakuyousi"(one of hard paper in Japan) 5sheets
-Scotch tape(Sellotape) 3pieces
-Packaging tape(parcel tape) 1piece

[Main materials]
-EVA foam
→2mm or 1.5mm thick 100cm X 50cm
→5mm thick 100cm X 30cm
→10mm thick 100cm X 10cm
-Styrofoam
→30mm thick 100cm X 30cm
-"Kousakuyousi"(one of hard paper in Japan) 4sheets
-Plastic sheets 0.5mm thick 4sheets
-Synthetic leather 100cm X 10cm
-"Bond G17"(one of liqud glue in Japan) 100ml
-Wood glue 100ml
-Liquid super glue 12pieces
-"Black instant glue(one of instant glue in Japan) 1piece
-Polyester putty 100g
-Hot melt(glue gun) 27pieces (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 100ml
-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) 200ml
-lacquer thinner 200ml
-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
8600Yen (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
-Masking tape 1piece
-Paint tools, such as a paintbrush
-Tools for processing plastic sheets(sandpaper etc)

Convenient tools when you have
-Art knife PRO
-Circle cutter
-Heat gun
-Super glue Accelerator

Work time
80hours

Spec
Weight 1.6kg
Length 170cm

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 of the blade.
Make ground plan from "Kousakuyousi"(one of hard paper in Japan).
At first deside thick of every blade.
I decided the thick of blade is 4.2mm.



Put Templates on a flat board.
Make the height of half of decided thick of blade
Stick together several materials, and make height 2.1mm.


Paste the pattern paper of blade of inside.


Serve gap from end to end from Drawing paper and "Kousakuyousi"(one of hard paper in Japan).



Serve gap from end to end from Drawing paper and "Kousakuyousi"(one of hard paper in Japan).


Serve gap from end to end from Drawing paper and "Kousakuyousi"(one of hard paper in Japan).


Serve gap from end to end from Drawing paper and "Kousakuyousi"(one of hard paper in Japan).


Heaping was completed.


Peel.
Copy to new Drawing paper and make a fair copy.


Assemble the fair copy.


Assemble the fair copy.


When you make a ideal from, cut open it. Use it.


Make Templates of the grip end.
Make Templates from Drawing paper.
When you want to know detailed tutorial of making Templates, browse this page.


Repeat cutting and pasting.


When you make a ideal from, cut open it. Use it.


Make Templates of the grip end.
Make Templates from "Kousakuyousi"(one of hard paper in Japan).


Make the blade.
Cut out 30mm thick Styrofoam with styrol cutter.

←便利な卓上タイプ ←手軽な手持ち型

Cut out 30mm thick Styrofoam with styrol cutter.


Cut out 30mm thick Styrofoam with styrol cutter.


Cutting was completed.


Cut out 2mm or 1.5mm thick EVA foam.
Glue with Wood glue.


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

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.

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


【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.

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




Cut unnecessary points with Box cutter.


Cross section.


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.


Glue with a Hot melt(glue gun).



Glueing was completed.


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


【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】


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.

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


Glueing was completed.


Glue to the opposite face.
Glue with Wood glue.


Glueing was completed.


Copy the edges of Templates on a material with a pen.
Cut out 10mm thick EVA foam.


【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】


Glue with a Hot melt(glue gun).


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.


Temporal tack with Masking tape.



Glue with a Hot melt(glue gun).


Glue with a Hot melt(glue gun).


Glueing was completed.


Copy the edges of Templates on a material with a pen.
Cut out 0.5mm thick Plastic sheets.


Glue with a Liquid super glue.


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


Heap "Black instant glue(one of instant glue in Japan) on the joint etc.



Heaping was completed.


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


Heap Polyester putty on the joint etc.

←120g ←1kg

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


Thin lacquer putty with lacquer thinner.



Paint lacquer putty thined lacquer thinner on hollows and cracks.


Polish with Sand paper of around 400grit.


If there are cracks and hollows yet, repeat heaping and polishing.

Polishing was completed.


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


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


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


Marking was completed.


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



Draw patterns with a Hot melt(glue gun).


Drawing was completed.


Glue to the blade.
Glue with a Liquid super glue.


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


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


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


Marking was completed.


Glue with a Liquid super glue.


Cut out for making a hollow.


Shift the position. Glue with a Liquid super glue.


The hollow was made.


Glue with a Liquid super glue.
Heap a Hot melt(glue gun) for reinforcement.


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


Glue with a Liquid super glue.


Glue with a Liquid super glue.


Heap a Hot melt(glue gun) for reinforcement.


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


Cut out for making a hollow.


Shift the position. Glue with a Liquid super glue.


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


Glue with a Liquid super glue.


Glue with a Liquid super glue.


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)

←ガス充填式ライターとガスボンベを使うとお得

Draw patterns with a Hot melt(glue gun).


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


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.


Glue with a Liquid super glue.


Bend by heating with a Lighter or a Heat gun.



Cut out for making a hollow.


Shift the position. Glue with a Liquid super glue.
The hollow was made.


Draw patterns with a Hot melt(glue gun).


Draw patterns with a Hot melt(glue gun).


Glue with a Hot melt(glue gun).


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



Form by shaving with a Box cutter.


Remove the corner by toasting with a Lighter.(Don't breathe in the smoke and don't put in eyes)


Glue with a Liquid super glue.


Make the grip.
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.


Glue with a Liquid super glue.


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


Glue with a Liquid super glue.


Cut it into slant with a Box cutter.


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


Glue with a Liquid super glue.


Glue with a Liquid super glue.


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


Cut the corner into slant with a Box cutter.


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)


Pass PVC pipe through parts.
Glue with a Liquid super glue.
Heap a Hot melt(glue gun) for reinforcement.


Draw patterns with a Hot melt(glue gun).


Draw patterns with a Hot melt(glue gun).


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.


Dry it about 2 ~ 6 hours.


Paint black color as undercoat color with Lacquer Spray.


Paint black color as undercoat color with Lacquer Spray.


Paint black color as undercoat color with Lacquer Spray.


Drybrush paint purple color Bottle lacquer paint with a paint brush.


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 white color of Bottle lacquer paint with a paint brush.


Paint silver Bottle lacquer paint by Drybrush painting.


Cut Synthetic leather into a belt form.



Glue with a Hot melt(glue gun).


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Dismantle state.


Joint girp and blade.


Thrust the wood stick.


Insert the grip.
Complete.


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