DRAGON BALL
How to make Trunks's sword (with templates)

*Sheath tutorial is here


Watch tutorial video at first


Materials for the sword
[Materials for making templates]
-"Kousakuyousi"(one of hard paper in Japan) 5sheets

[Main materials]
-EVA foam
→1.5mm or 2mm thick 100cm X 10cm
→5mm thick 100cm X 10cm
→10mm thick 100cm X 10cm
-"Kousakuyousi"(one of hard paper in Japan) 4sheets
-Synthetic leather 100cm X 20cm
-"Bond G17"(one of sticky glue in Japan) 100ml
-Liquid super glue 3pieces
-Hot melt(glue gun) 10pieces
-PVC pipe(diameter 2.6cm) 1piece
-Iron gardening stick(diameter 0.8cm) 1piece

[Painting materials]
1.When undercoat is Gesso
-Gesso 50ml
-Paintbrush 1piece
-lacquer paint(Bottle lacquer paint, Lacquer Spray etc) or acrylic paint proper quantity*

2.When undercoat is Wood glue thinned with water
-Wood glue 50ml
-Water a little
-Paintbrush 1piece
-Paper cup, bowl etc 1piece
-lacquer paint(Bottle lacquer paint, Lacquer Spray etc) proper quantity*

3.When undercoat is Thinned "Bond G17"(one of liqud glue in Japan)
-"Bond G17"(one of sticky glue in Japan) 50ml
-lacquer thinner 50ml
-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 to make the sword
2000Yen (about 130Yen = 1dollar)

Tools
-Writing implement(Pencil,eraser,ballpoint,Magic Marker,ruler)
-Paste
-Scissors
-Box cutter etc(Use also a "Pro blade" and a "Blade breaker")
-Cutting mat
-Hot melt(glue gun)
-Pipe cutter or Saw
-Paint tools (brush etc)
-Tools to cut Iron gardening stick(Freeway coping saw, Nippers, etc)

Convenient tools when you have
-Standard art knife,Cushion grip art knife
-Super glue Accelerator

Work time to make the sword
10hours

Spec
-Sword
Weight 210g
Length 100cm

-Sheath
Weight 200g
Length 83cm

Template data
PDF format(A4 size)

How to download & print
Read this.

About commercial use
Please follow this rule.

Additional explanation
-After printing, it becomes easy to use by sticking it on Drawing paper with spray glue.
-Mentions of "x1","x2" etc are the numbers of sheets.
(If you need both arms or both legs etc, cut the number of double.)
-Mentions of "2mm" , "5mm" etc are thickness of EVA foam.

Completion image
Caution Bellow photo is a image photo aftet completing.
Caution Don't print bellow photo.
Caution Read "How to print".


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.

-If accedents happens, it's self-responsibility. Keep safety environment.

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More history

Make the template
Make Templates from "Kousakuyousi"(one of hard paper in Japan).
When you want to know how to make Templates of weapons, browse this page.



Building the blade


Cut "Kousakuyousi"(one of hard paper in Japan) into a belt form.


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


Paste them



"Kousakuyousi"(one of hard paper in Japan) is sold in only Japan.
It's harder than Drawing paper. The thickness is about 0.5mm.
I'm sure you can't get it.
Then, substitute various thin plastic sheets.


Cut material into the Templates form.
Cut out "Kousakuyousi"(one of hard paper in Japan).


Crease by tracing with a ballpointpen.
(The red line is the crease.)


I finished creasing.


Glue the tip of sword.
Glue with a Hot melt(glue gun).


ギャクヨガが愛用しているグルーガンです、口が広くてとても使いやすい!

Use it as a core.
Cut it wit nippers, Freeway coping saw, etc.
This stick is just a iron stick.
You can substitute various metalic sticks.


園芸用の棒はホームセンターや100均で買った方が安い。



I finished cutting.


Glue with a Hot melt(glue gun).


Glue with a Hot melt(glue gun).


I finished glueing.


Glue edges of the blade.
Glue with "Bond G17"(one of sticky glue in Japan). Detailed process is here.
Paint it with a broken piece of "Kousakuyousi"(one of hard paper in Japan) as a brush.
Don't use fire until drying, because "Bond G17" burns easily. Don' use a Lighter etc until drying.


チューブ入り(箱入り)の方が使い勝手はいいですが、缶入りの方がコスパは断然良いです。

Reinforce the blade by applying Liquid super glue on the edge.


Cut material into the Templates form.
Cut out 1.5mm or 2mm 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.)





EVA foam is soft material.
You can process it easily.
Other names are EVA board, EVA zote, Craft foam etc.
Cosplayers all over the world use this.
It's sold in Amazon or AliExpress etc.

Introduction video




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

I always use "Running fire box cutter","Blade breaker",Cutting mat.
"Blade breaker" can break the blade easily.


Use Standard art knife or Cushion grip art knife to cut small ornaments etc, too.
Standard art kinfe is for 1.5mm thickness and 3mm thickness.
Cushion grip art knife is for 5mm thickness and 10mm thickness.



↑刃はついてないので→の替え刃とセットで買うこと





●1.5mm厚コスプレボードを楽天で買う


送料無料の5枚セット



●1.5mm厚コスプレボードをAmazonで買う


●2mm厚COSボード匠を楽天で買う(COSボード匠はAmazonでは売ってません)






Super glue accelerator makes hardening time short.
It's so useful.
Watch this video.


When you use 100ml, you can make a armorset or about two, three weapons.



I finished glueing.


Building the guard


Cut material into the Templates form.
Cut out 10mm thick EVA foam.





●10mm厚コスプレボードを楽天で買う


●10mm厚コスプレボードをAmazonで買う


●10mm厚COSボード匠を楽天で買う(COSボード匠はAmazonでは売ってません)



Glue with a Liquid super glue.


Form by shaving with a Box cutter etc.


Make the edges smooth with a Soldering iron (Don't breathe in the smoke, be careful a burn).
Or, cut it by edged tools.
(Actually I used fire, but it's dangerous method. I recommend a Soldering iron
If accedents happens, it's self-responsibility)



Glue with a Liquid super glue.


Building the hilt


Use a PVC pipe(diameter 2.6cm).
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.


I finished cutting.


Glue with a Hot melt(glue gun).


I finished glueing.


Cut material into the Templates form.
Cut out 1.5mm or 2mm thick EVA foam.


Glue with a Liquid super glue.


Cut material into the Templates form.
Cut out 5mm thick EVA foam.
Cut out 10mm thick EVA foam.





●5mm厚コスプレボードを楽天で買う


送料無料の5枚セット


●5mm厚コスプレボードをAmazonで買う


●5mm厚COSボード匠を楽天で買う(COSボード匠はAmazonでは売ってません)



Glue with a Liquid super glue.


Shave it into a mountain form with a Box cutter etc.


Bend it with a Heat gun or Steam iron while pushing the shaving side.
(Actually I used fire, but it's dangerous method. I recommend Heat gun or Steam iron.
If accedents happens, it's self-responsibility)



Glue with a Liquid super glue.


Glue with a Liquid super glue.


I finished glueing.


Present state.



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Painting
Begin painting.
At first, paint 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.


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
黒いジェッソと詰替えパック


白いジェッソと詰替えパック



2.Wood glue thinned with water
This is so easy.

【Merit】
-Someone can get
-Someone can use easy

【Demerit】
-Drying time is a little long.

【Commodities page】


3."Bond G17"(one of liqud glue in Japan)
This is dangerous method, it's most likely happening fire.
I wrote about this method as a archive,
However I don't recommend this.
I don't use this method now, I use other method now.
If accedents happens, it's self-responsibility.

【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.
-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.

【Commodities page】
"Bond G17"(one of sticky glue in Japan) thined with lacquer thinner

チューブ入り(箱入り)の方が使い勝手はいいですが、缶入りの方がコスパは断然良いです。



-About paint
I use following paint.


You can use acrylic paint, when you use Gesso.


・About mask
In spray painting or lacquer painting, use a mask for painting.
←フィルタ付きセット商品 ←替えフィルタ


I use "Zoukei be-su" as undercoat this time.
But it's sold only in Japan.
Substitute Gesso or Wood glue thinned with water.


Paint "Zoukei be-su" twice with a brush.
Dry it about 2 ~ 6 hours.


Paint black color as undercoat color with Lacquer Spray.


Paint silver with Lacquer Spray.


Paint silver 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 thinner, sticks for mixing, brushes, cups.





After painting
Cut out Synthetic leather.


Glue with a Hot melt(glue gun).


Complete


Please watch the tutorial video too.
















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