How to make Halberd (with templates)


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

[Main materials]
-EVA foam
→1.5mm or 2mm thick 100cm X 10cm
→5mm thick 100cm X 10cm
-"Kousakuyousi"(one of hard paper in Japan) 5piece
-"Bond G17"(one of sticky glue in Japan) 50ml
-Liquid super glue 3piece
-Hot melt(glue gun) 10piece
-Wire 100cm
-PVC pipe(diameter 2.6cm) 1piece
-Materials to make PVC pipe jointing stick 25cm

[Painting materials]
1.When undercoat is Gesso
-Gesso 100ml
-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 100ml
-Water a little
-Paintbrush 1piece
-Paper cup, bowl etc 1piece
-lacquer paint(Bottle lacquer paint, Lacquer Spray etc) proper quantity*
-Masking tape 1piece

3.When undercoat is Thinned "Bond G17"(one of liqud glue in Japan)
-"Bond G17"(one of sticky glue in Japan) 100ml
-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
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)
-Soldering iron and soldering iron stand
-Pipe cutter or Saw
-Tools to make PVC pipe jointing stick
-Freeway coping saw
-Paint tools (brush etc)
-Pinvice or Prick punch etc
-Nippers

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

Work time
18Hours

Spec
Weight 1kg
Length 200cm

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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Nov,30,24
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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
Make 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 out "Kousakuyousi"(one of hard paper in Japan).


Cut out 5mm thick EVA foam.
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.)





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





●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)






●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)






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.



Glue edges of the blade.
Glue with "Bond G17"(one of sticky glue in Japan).
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。

I finished glueing.


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


I finished glueing.


Fill the back of blade with a Hot melt(glue gun).


Building the shaft(first half)
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.


Make a joint stick.
The length is 25cm.
Cut Iron gardening stick. How to cut is here.
Cut out 1.5mm or 2mm thick EVA foam.
Glue with a Liquid super glue.


Cut the tip with a Freeway coping saw.
If you feel this process is difiicult, there is a other method. Details are here.



Put between the tip.
Glue with a Hot melt(glue gun).


I finished glueing.


Cut out 5mm thick EVA foam.
Glue with a Liquid super glue.


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)



Draw patterns with a Hot melt(glue gun).


Building the small blade
Cut out "Kousakuyousi"(one of hard paper in Japan).
Crease by tracing with a ballpointpen.
(The red line is the crease.)


Make crease to blade.


Heap a Hot melt(glue gun) for reinforcement.


Use a Aluminum stick.
You can substitute various metalic sticks.
Cut it into appropriate length with Nippers.


Glue the Aluminum stick.
Glue with a Hot melt(glue gun).


Glue another blade.
Glue with a Hot melt(glue gun).


Paste Liquid super glue to edge of blade.


Make hole with a Pinvice or Prick punch etc.



It can fit to insert.


Building the shaft(latter half)
Cut out 1.5mm or 2mm thick EVA foam.
Mark pattern by penn.





●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)



Carve the pattern with a Soldering iron.
(Don't breathe in the smoke and don't put in eyes. If accedents happens, it's self-responsibility.)


ギャクヨガが使っているハンダゴテです、安全の為に台も買いましょう。

Glue with a Liquid super glue.


Cut out 5mm thick EVA foam.
Glue with a Liquid super glue.


Make a stick end.
Cut out 1.5mm or 2mm thick EVA foam.


Heap a Hot melt(glue gun) for reinforcement.


Glue with a Hot melt(glue gun).
The edge breaks easily, then cut it.


Present state.



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Painting
Stand the cylinder form parts with a wood struck big nails.


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 Thinned "Bond G17"(one of liqud glue in Japan) in this tutorial.
But this method is danger, then I don't recommend.
If accedents happens, it's self-responsibility.
I recommend Gesso or Wood glue thinned with water.
*When you use Gesso, don't paint it on the PVC pipe. Beforehand do this process.
Or glue Synthetic leather with "Bond G17"(one of sticky glue in Japan).


Paint "Bond G17"(one of sticky 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.


Paint black color as undercoat color with Lacquer Spray.


Paint silver with Lacquer Spray.


Actually, I used a Airbrush too.
If you want to make light and shade, use it.
About Airbrush is here.





●初心者にオススメ
安価なUSB充電式エアブラシ。
これ一つでエアブラシ塗装が手軽に行えます。
エアブラシ塗装を手軽に始めるならまずはこれ。


●ギャクヨガが使っている物を使いたいなら
性能は高いですが本格的です。
左がエアブラシ本体、右が空気を送り出す装置で両方必要です。



Paint Bottle lacquer paint with a paint brush.


When you paint Bottle lacquer paint, use thinner, sticks for mixing, brushes, cups.






Complete


















Visitor's works

るりさん
Fate/GO ギルガメッシュ(キャスター) 斧
ギャクヨガ様の手斧とハルバードの作り方を参考に制作。
本体はスプレー、棒は布を貼。
本体の棒を通す穴はイラストに近付けるためと補強も兼ねて
上からもう一枚ライオンボード貼り付けました。
約175cm1.2kg




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