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



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

[Main materials]
-"Lion Board(Koyo Soft Board)"
→2mm thick(1.5mm is also OK) 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 instant glue 12pieces
-"Black instant glue(one of instant glue in Japan) 1piece
-Polyester putty 100g
-Hot melt(glue gun) 27pieces (It's convenient if there is also Air duster for cooling)
-PVC pipe(diameter 32.0mm) 1piece
-Stick for jointing PVC pipe 25cm

[Painting materials]
1.Case of Gesso painting
-Gesso 100ml
-lacquer paint(Bottle lacquer paint, Lacquer Spray etc) or acrylic paint proper quantity*

2.Case of "Bond G17" painting
-"Bond G17"(one of liqud glue in Japan) 200ml
-lacquer thinner 200ml
-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
8600Yen (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)
-Masking tape 1piece
-Paint tools, such as a paintbrush
-Things required for processing plastic sheets(sandpaper etc)

Convenience tools when you have
-Art knife PRO
-Circle cutter
-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
80hours

Spec
Weight 1.6kg
Length 170cm

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



Put Pattern paper 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 with Drawing paper and "Kousakuyousi"(one of hard paper in Japan).



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


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


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


Serving was completed.


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


Assemble fair copy again.


Assemble fair copy again.


When you make ideal form, it's cut open.Let it be formal Pattern paper.


Make Pattern paper of the grip end.
Make Pattern paper by Drawing paper.
When you want to know how to make fundamental Pattern paper,watch this page.


Cut and paste and brings close ideal form.


When you make ideal form, it's cut open.Let it be formal Pattern paper.


Make Pattern paper of the grip end.
Make Pattern paper by "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 out was completed.


Cut out 2mm(1.5mm is also OK) thick "Lion Board(Koyo Soft Board)".
Stick together with Wood glue.


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

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.

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




Cut unnecessary points with Box cutter.


Cross section.


Make a core.
Use PVC pipe(diameter 32.0mm).
Cut PVC pipe. PVC pipe can be cut by saw. But Pipe cutter is more bettr.Pipe cutter can cat quickly and beautifull.



Make block construction for carrying.


Paste with Hot melt(glue gun).



Pasting was completed.


Copy the edges of Pattern paper on a material with a pen.
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.
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.


Glue to poosite face.
Paste together with Wood glue.


Pasting was completed.


Copy the edges of Pattern paper on a material with a pen.
Cut out 10mm thick "Lion Board(Koyo Soft Board)".


【10mm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。


【10mm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】


【10mm厚COSボードをネット通販で買う】


【10mm厚COSボードを楽天市場で買う】


Paste with Hot melt(glue gun).


Put "Kousakuyousi"(one of hard paper in Japan) side by side.
And paste 0.5mm thick Plastic sheets straddling borderline of "Kousakuyousi"(one of hard paper in Japan) with "Bond G17"(one of liqud glue in Japan).
Don't use fire after painting until drying, because "Bond G17"burns easily. Don' use Lighter etc until drying.
After this,side of Plastic sheets is used as face, side of "Kousakuyousi"(one of hard paper in Japan) is used as back.
(Reinforcement purpose.If it does not care about intensity,using only "Kousakuyousi"(one of hard paper in Japan) is OK.)



Copy the edges of Pattern paper on a material with a pen.
Cut out the glued board.


Temporal tack with Masking tape and decide position.



Paste together with Hot melt(glue gun).


Paste together with Hot melt(glue gun).


Pasting was completed.


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


Paste together with Liquid instant glue.


Paste together edge of blade with Liquid instant glue.


Serve "Black instant glue(one of instant glue in Japan) to the joint etc.



Serving was completed.


Polish position served place with about 120 ~ 400 grit sand paper.


Serve Polyester putty to joint etc.

←120g ←1kg

Polish position served place with about 120 ~ 400 grit sand paper.


Thin lacquer putty wiht lacquer thinner.



Paint lacquer putty thined lacquer thinner to hollows and flaws.


Polish Sand paper(around 400grit).


If there are Crack and hollow yet, repeat serving and polishing.

Polishing was completed.


Copy the edges of Pattern paper on a material with a pen.
Cut out 2mm(1.5mm is also OK) thick "Lion Board(Koyo Soft Board)".


Mark position of hole by penn using Pattern paper.


Mark position of hole by penn using Pattern paper.


Marking was completed.


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



Write pattern with Hot melt(glue gun).


Writing was completed.


Glue to the blade.
Paste with Liquid instant glue.


Make the grip guard.
Copy the edges of Pattern paper on a material with a pen.
Cut out 5mm thick "Lion Board(Koyo Soft Board)".


Mark position of hole by penn using Pattern paper.


Mark position of hole by penn using Pattern paper.


Marking was completed.


Paste together with Liquid instant glue.


Cut out for making difference in level.


Shift position, and Paste together with Liquid instant glue.


Difference in level was made.


Paste together with Liquid instant glue.
Serve Hot melt(glue gun) as reinforce to inside.


Copy the edges of Pattern paper on a material with a pen.
Cut out 5mm thick "Lion Board(Koyo Soft Board)".


Paste together with Liquid instant glue.


Paste together with Liquid instant glue.


Serve Hot melt(glue gun) as reinforce to inside.


Copy the edges of Pattern paper on a material with a pen.
Cut out 2mm(1.5mm is also OK) thick "Lion Board(Koyo Soft Board)".


Cut out for making difference in level.


Shift position, and Paste together with Liquid instant glue.


Copy the edges of Pattern paper on a material with a pen.
Cut out 5mm thick "Lion Board(Koyo Soft Board)".


Paste together with Liquid instant glue.


Paste together with Liquid instant glue.


Paste together with Liquid instant glue.


Toast with Lighter and remove corner.(Don't breathe smoke,don't let smoke meets eyes)

←ガス充填式ライターとガスボンベを使うとお得

Write pattern with Hot melt(glue gun).


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


Copy the edges of Pattern paper on a material with a pen.
Cut out 5mm thick "Lion Board(Koyo Soft Board)".


Paste together with Liquid instant glue.


Copy the edges of Pattern paper on a material with a pen.
Cut out 5mm thick "Lion Board(Koyo Soft Board)".


Paste together with Liquid instant glue.


Heat with Lighter and bend.


Cut out for making difference in level.


Shift position, and Paste together with Liquid instant glue.
Difference in level was made.


Write pattern with Hot melt(glue gun).


Write pattern with Hot melt(glue gun).


Paste together with Hot melt(glue gun).


Cut out 10mm thick "Lion Board(Koyo Soft Board)".
Tools are needed to cut out beautiful circle form.Details are here.)



Shave form with Box cutter.


Toast with Lighter and remove corner.(Don't breathe smoke,don't let smoke meets eyes)


Paste with Liquid instant glue.


Make the grip.
Copy the edges of Pattern paper on a material with a pen.
Cut out 5mm thick "Lion Board(Koyo Soft Board)".
Cut out 2mm(1.5mm is also OK) thick "Lion Board(Koyo Soft Board)".


Paste together with Liquid instant glue.


Paste together with Liquid instant glue.


Copy the edges of Pattern paper on a material with a pen.
Cut out 5mm thick "Lion Board(Koyo Soft Board)".


Paste together with Liquid instant glue.


Cut slant with Box cutter for making acute angle.


Copy the edges of Pattern paper on a material with a pen.
Cut out 5mm thick "Lion Board(Koyo Soft Board)".


Paste together with Liquid instant glue.


Paste together with Liquid instant glue.


Cut out 10mm thick "Lion Board(Koyo Soft Board)".
Tools are needed to cut out beautiful circle form.Details are here.)


Cut corner slant with Box cutter.


Paste together with Liquid instant glue.


Toast with Lighter and remove corner.(Don't breathe smoke,don't let smoke meets eyes)


Pass PVC pipe through parts.
Paste together with Liquid instant glue.
Serve Hot melt(glue gun) as reinforce.


Write pattern with Hot melt(glue gun).


Write pattern with Hot melt(glue gun).


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.
-------------------------------------------------------------------------------------------
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
-------------------------------------------------------------------------------------------

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

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

In subsequent explanation is use "Bond G17" painting.
But Gesso painting is easy to use.
*Case of Gesso painting,don't paint Gesso to plastic sheet part.

Paint "Bond G17"(one of liqud glue in Japan) thined with lacquer thinner at 3 or 4 times.
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.
Desiccate for 4 or 5 hours.(It may become dry for 1 or 2 hours, but Desiccating for 4 or 5 hours is better.)


Desiccate for 4 or 5 hours.(It may become dry for 1 or 2 hours, but Desiccating for 4 or 5 hours is better.)


Stand to wood struck big nail.


Desiccate for 4 or 5 hours.(It may become dry for 1 or 2 hours, but Desiccating for 4 or 5 hours is better.)


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 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.


Paint white color of Bottle lacquer paint with paintbrush.


Drybrush paint silver color Bottle lacquer paint with paintbrush.
(You can Drybrush paint easy with blush. Details are here.)


Cut Synthetic leather to belt form.




Paste with Hot melt(glue gun).


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


















Dismantle state.


Joint girp and blade.


Thrust the wood stick.


Insert the grip.
Complete.


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