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Touken Ranbu
How to make Otegine's spear (with pattern)



Materials

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

[Main materials]
-"Lion Board(Koyo Soft Board)"
→2mm thick(1.5mm is also OK) 100cm X 10cm
→5mm thick 100cm X 20cm
-"Kousakuyousi"(one of hard paper in Japan) 4sheets
-Synthetic leather 100cm X 20cm
-Liquid instant glue 1piece
-Hot melt(glue gun) 10pieces (It's convenient if there is also Air duster for cooling)
-PVC pipe(diameter 18.0mm) 1piece
-Stick for jointing PVC pipe 25cm
-Iron gardening stick 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*
-Masking tape 1piece

*Paiting are is written in the package, refer it. Detail is here.

Materials cost
1500Yen (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
-Saw(Pipe cutter is also OK)
-Sand paper(240grit)
-Paint tools, such as a paintbrush

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
8hours

Spec
Weight 350g
Length 200cm

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

-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 "Lion Board(Koyo Soft Board)".

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 by "Kousakuyousi"(one of hard paper in Japan).


Make the blade.
Paste "Kousakuyousi"(one of hard paper in Japan) cut beltlike by Hot melt(glue gun).
Some "Kousakuyousi"(one of hard paper in Japan) ties to one sheet.



Copy the edges of Pattern paper on a material with a pen.
Cut out "Kousakuyousi"(one of hard paper in Japan).


Paste.


Trace to position you want to make crease with ballpointpen, and ake crease.<br>
(Red line is crease.)


Tracing was completed.


Use Iron gardening stick as core.
Cut Iron gardening stick to length with a sufficient degree with pliers.
Cutting with Freeway coping saw is easiest and most cutting beautifull.
Pliers and nippers and diamond files are alos OK, but they take time.



Paste with Hot melt(glue gun).



Paste one more blade with Hot melt(glue gun).


Serve with Hot melt(glue gun) as reinforce to tip of blade.


Serving was compelted.


Paste edge of blade with "Bond G17"(one of liqud glue in Japan).
Using broken piece of "Kousakuyousi"(one of hard paper in Japan) as brush is convenience.
Don't use fire after painting until drying, because "Bond G17"burns easily. Don' use Lighter etc until drying.



Paste Liquid instant glue to edge of blade for reinforce.


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)".
Tools are needed to cut out beautiful circle form.Details are here.)


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

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.
*******************************************************************************************


【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】


【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.

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


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

Paste with Liquid instant glue.


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)".


Paste with Liquid instant glue.


Make a stick part.
Use PVC pipe(diameter 18.0mm).
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.


Use stick for joint. 25cm is best of lenght.

-------------------------------------------------------------------------------------------
[1]Iron gardening stick sticked "Lion Board(Koyo Soft Board)"(Taking time, however so good method)

Use Iron gardening stick thinner than PVC pipe as a core.
Cut Iron gardening stick. How to cut is here.
Cut out 2mm(1.5mm is also OK) thick "Lion Board(Koyo Soft Board)".
Paste with Liquid instant glue.
It takes time, but joint power is high and it don't becomes loose.

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

-------------------------------------------------------------------------------------------
[2]Wood stick(Easy method, but it becomes loose)

Insert wood stick to PVC pipe in shop,and search good thickness wood stick.
If you can't search it,buy big size.And shave it with Box cutter.
This method is easy. But it is shaved when it is used, and it becomes loose.

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

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.)



Paste with Hot melt(glue gun).


Pasting was completed.


Present state.


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,PVC pipe can't paited direct.Beforehand do this process.
Or paste Synthetic leather with "Bond G17"(one of liqud glue in Japan).


Stand to wood struck big nail.


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.)


Paint gray color as undercoat color with Lacquer Spray.


Paint black color as undercoat color with Lacquer Spray.


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



Paint silver color with Lacquer Spray.



Polish cloth or tissue paper after drying and make brilliance.


Paint blown with Lacquer Spray.


Paint blown with Lacquer Spray.


Stick Masking tape so that paint may not adhere to unrelated place.
Maskig all with Masking tape is wasteful.So use newspaper too.
Paint gold with Lacquer Spray.


Paint gloss spary to make gloss.



Cut Synthetic leather to belt form.


Paste with Hot melt(glue gun).


Pasting was completed.


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














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