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featherweight
02-17-2006, 06:10 PM
This is a tutorial to a basic katana whcih building methods can be apiled to most katana type swords and still be cost effective.

here are examples of this style i have built
http://images.cosplay.com/showphoto.php?photo=542865
http://images.cosplay.com/showphoto.php?photo=548465
http://images.cosplay.com/showphoto.php?photo=650574
http://images.cosplay.com/showphoto.php?photo=718363

(new wonderful photoshopped verson has been added photoshoping done by Najica with my thanks)

http://i12.photobucket.com/albums/a241/featherweight-cosplay/ck-101-01.jpg
http://i12.photobucket.com/albums/a241/featherweight-cosplay/Cardboard%20katana%20v2/ck01v2.jpg
http://i12.photobucket.com/albums/a241/featherweight-cosplay/Cardboard%20katana%20v2/ck02v2.jpg
http://i12.photobucket.com/albums/a241/featherweight-cosplay/Cardboard%20katana%20v2/ck03v2.jpg
* http://images.cosplay.com/showphoto.php?photo=631505 *
http://i12.photobucket.com/albums/a241/featherweight-cosplay/Cardboard%20katana%20v2/ck04v2.jpg
http://i12.photobucket.com/albums/a241/featherweight-cosplay/Cardboard%20katana%20v2/ck05v2.jpg
http://i12.photobucket.com/albums/a241/featherweight-cosplay/Cardboard%20katana%20v2/ck06v2.jpg
http://i12.photobucket.com/albums/a241/featherweight-cosplay/Cardboard%20katana%20v2/ck07v2.jpg
http://i12.photobucket.com/albums/a241/featherweight-cosplay/Cardboard%20katana%20v2/ck08v2.jpg
http://i12.photobucket.com/albums/a241/featherweight-cosplay/ck-101-10.jpg

*long blade tips update* http://i12.photobucket.com/albums/a241/featherweight-cosplay/longbladetips.jpg
1) for the last last 2/3's of the blade make the gain of the cardboard on the two outer layers run with the lenght of the blade.
(this wil give a stearth boost but would be redonedent on a blade under around 4 feet long)


2) instead of cutting the dowel snap it so you get two frayed ends than useing a wood glue, glue them back togetter on an angel so it can be put in the blade (this one could be use for any sword you wanna add alittle extra stearth to)

doing thoose two things togetter should be enough to sapport a blade fiarly well to about alittle over 5 feet

if you do use this tutorial i would love to see pics of how things truned out

READ FAQ BEFORE ASKING QUESTIANS
it could save your life
FAQ-> http://forums.cosplay.com/showthread.php?p=1537838#post1537838

*UPDATE* -SHEATH TUTORIAL-

OK since so many poeple have asked about this i am writing this tutorail on how i build my sheaths now -new photoshoped verson done by Pazuzu

heres a photo of a sheaths finished using basicly this method
http://images.cosplay.com/showphoto.php?photo=718363
http://images.cosplay.com/showphoto.php?photo=889722

things you'll need
-cardboard
-hotglue and gun
-white glue
-sweat suit cloth
-thread and other sewing things
-exacto knives
-paint and brushs

http://i12.photobucket.com/albums/a241/featherweight-cosplay/Sheath01.jpg
http://i12.photobucket.com/albums/a241/featherweight-cosplay/Sheath02.jpg
http://i12.photobucket.com/albums/a241/featherweight-cosplay/Sheath03.jpg
http://i12.photobucket.com/albums/a241/featherweight-cosplay/Sheath04.jpg
http://i12.photobucket.com/albums/a241/featherweight-cosplay/Sheath05.jpg

ok thats it.

*UPDATE* -BROADSWORD TUTORIAL-
while some of you ask if you can use the katana style built a western style broadsword it just doesn't work. So heres a new tutorial which can be apiled to most broadswords

ok i'm doing things alittle diffrent this time instead of my bad handwritin i'll just tpye the instructions in the thread and just macth up the numbers with the pictures its faster for me and easyer for you but agian if anyoen wants to photoshop the two togetter pm me . ( note the drawings are abit nicer this is do to the fact i only had an inch long pencil to draw the katana one, man my hand killed) also this is really only meant as an expansion pack to the katana tutorial it uses pretty much the same matrails and skill set so thing are alittle less explianed in this one its best read the katana tutorial frist to know whats going on ;)

heres the sorwd i made using this style of build
http://images.cosplay.com/showphoto.php?photo=644813
http://images.cosplay.com/showphoto.php?photo=755782
http://images.cosplay.com/showphoto.php?photo=1259322

http://i12.photobucket.com/albums/a241/featherweight-cosplay/bst01.jpg

1. crave a 3/8" dowel so the tip is flat starting from about 10 inchs up the dowel
2. cut a long piece of cardboard in to the shape of the the blade(note the holes should be at the sides) , cut a 3/8" slit down the middle starting about 1 1/2" from the tip than glue it to the dowel so the flat tip on it is level with the board make sure thier is still atlest 6' of dowal extanding form the back of the blade for the handle later
3. cut two peices the same shape and the blade but about 3/8" smaller allround (holes at the sides agian)
4.cut down the middle of the pieces but not all the way though the board than bend the pieces along that crack

http://i12.photobucket.com/albums/a241/featherweight-cosplay/bst02.jpg

5. glue the two pieces on to the blade in the milddle so the crack lines up with the dowal the pieces should be fluse back of the blade and have an even
gap all aroud the cutting edge
6. fill and smooth the gap of the blade with glue also the very edge of the blade should be filled

http://i12.photobucket.com/albums/a241/featherweight-cosplay/bst03.jpg

7. cut and remove stectoins from of the outter pieces of the blade they should be alttle less the half the length of the blade and the sides should be atlest 1/4" from the start of the glue egdes
8. cut new flat peices to in the space left by the one removed
9. glue fill the inner egdes on the so they bevel inword

http://i12.photobucket.com/albums/a241/featherweight-cosplay/bst04.jpg

10. glue fill and smooth the crack of the blade
11.built the handle be layering cruve pieces of cardboard around the pieces of dowal at the end of the blade than glue a disk to the very end made of layerd board with glue filled sides

http://i12.photobucket.com/albums/a241/featherweight-cosplay/bst05.jpg

12. cut and and glue pieces down to make up the hilt
13. glue fill and smooth all the edges of the hilt
14. paint the sword, acrylics tends to work well on theese materials

http://i12.photobucket.com/albums/a241/featherweight-cosplay/bst06.jpg

ok heres the links to my other tutorials too
kunai/Shurkien thread
http://forums.cosplay.com/showthread.php?t=71070&highlight=featherweight
automail thread
http://forums.cosplay.com/showthread.php?t=70438&highlight=featherweight
Kingdom Key thread
http://forums.cosplay.com/showthread.php?t=80141
i say how to make glue webbing here
http://forums.cosplay.com/showthread.php?t=74108&highlight=featherweight

postscript. hope you might find this useful and if you do use this i would love to see the results

fightstar
02-17-2006, 07:39 PM
*bows repeatedly* Once again Sensei Featherweight son has blessed us with another fine creation. Even a tutorial on how he did it. Oh, what a wonderful weekend it is. Major domo Featherweight Son. *passes the Saki*

~Kunoichi~Baka~
02-17-2006, 07:46 PM
COOL ^_____^!...That's better than bringing my iaito >>;...

meowl
02-17-2006, 07:56 PM
keep the faith!

Vicky
02-17-2006, 08:26 PM
This is a really great and cheap way of making a Katana. My boyfriend and I are going to try it for a cosplay he's doing (Jubei from Ninja Scroll) but we had a few questions that, between the two of us, couldn't figure out...

step 2: what does "running perpendicular to the length of the block so the holes are at the sides" mean?
step 20: "running parallel with the length of the blade"?
what happened to step 21?
step 24: Shapeding?

Lastly, would it be alright if we made a photo tutorial for this? i think a lot of people might find some of it confusing ^^;;

Master1080
02-17-2006, 08:56 PM
Nice tutorial. Looks like it will use a lot of hot glue though. Would you recommend using regular white Elmer's glue in someplaces instead?

Annie-Mei
02-17-2006, 09:08 PM
nicely done. I going ot have to build a small version of a katana in the near future, but ti will be made from foam instead; though the applications in this tutorial will be similar. Thanks for posting.

shiro.youma
02-18-2006, 12:08 AM
I can't get over what you are able to do with cardboard.

stefaniecat
02-18-2006, 01:07 AM
YEs! This just made my day!

I was inspired by your kunai tutorial to make cardboard weapons for Anime LA last month (and I'm quite proud of my ax, though its not perfect) and since I have a ninja costume in the works, this is exactally what I needed!

Thank you for more amazement and cardboard magic.

featherweight
02-18-2006, 05:01 AM
This is a really great and cheap way of making a Katana. My boyfriend and I are going to try it for a cosplay he's doing (Jubei from Ninja Scroll) but we had a few questions that, between the two of us, couldn't figure out...

step 2: what does "running perpendicular to the length of the block so the holes are at the sides" mean?
step 20: "running parallel with the length of the blade"?
what happened to step 21?
step 24: Shapeding?

Lastly, would it be alright if we made a photo tutorial for this? i think a lot of people might find some of it confusing ^^;;

http://i12.photobucket.com/albums/a241/featherweight-cosplay/DSC061891.jpg
you want thoose holes to be at the side of the blade it makes it easyer to fill iin and smooth over with glue

http://i12.photobucket.com/albums/a241/featherweight-cosplay/DSC06190.jpg
with the grain running with then blade the handle pieces bend better

step 22 is step 21 thats just a typoe i missed and "shapeding" should just be shading

i'd have to spend a week+ building a sword i wouldn't be using just to make a photo tutorial for this i don't have that kinda time so if you want to make one sure why not just rember to put my name in the credits

and the total cost to build one of theese is about $12-15

FeyMeggan
02-18-2006, 11:17 AM
wow, that was an amazingly simple, yet effective(in appearance, since I've not tried it) tutorial! that 12-15 bucks must be in glue alone LOL but it's amazing what you can do with so little supplies. While I don't need to make a sword(this time around) I plan to give that a try while making a set of Cerberus guns for my roommates Beyond the Grave outfit. Thanks so much for sharing!

Vicky
02-18-2006, 12:13 PM
http://i12.photobucket.com/albums/a241/featherweight-cosplay/DSC061891.jpg
you want thoose holes to be at the side of the blade it makes it easyer to fill iin and smooth over with glue

http://i12.photobucket.com/albums/a241/featherweight-cosplay/DSC06190.jpg
with the grain running with then blade the handle pieces bend better

step 22 is step 21 thats just a typoe i missed and "shapeding" should just be shading

i'd have to spend a week+ building a sword i wouldn't be using just to make a photo tutorial for this i don't have that kinda time so if you want to make one sure why not just rember to put my name in the credits

and the total cost to build one of theese is about $12-15

Aha! Yes, I think I get it now. I'll have to show this to my boyfriend, it's very helpful! Would you recommend similar methods of making other swords other than Katanas? Yes, of course we will credit the tutorial to you. We'll probably post it in this topic and you can add them to the first post, if you'd like :)
Thanks so much! We'll probably start working on it soon (we have to start collecting the cardboard, lol) so we'll let you know if we have any questions :)

ChrowX
02-18-2006, 12:23 PM
you know. I bow to your magnificent cardboard skills, but also applaud you for showing everyone that you can do more with cardboard than people think you can.

featherweight
02-18-2006, 03:01 PM
Aha! Yes, I think I get it now. I'll have to show this to my boyfriend, it's very helpful! Would you recommend similar methods of making other swords other than Katanas? Yes, of course we will credit the tutorial to you. We'll probably post it in this topic and you can add them to the first post, if you'd like :)
Thanks so much! We'll probably start working on it soon (we have to start collecting the cardboard, lol) so we'll let you know if we have any questions :)

frist i would only recomend this style of build to a single edged sword like a katana other swords tend to pose a whole other set of problems i've had to renvent the way i do things for the swords i'm working on now

also adding your photo tutorial is just fine with me

Zegen
02-18-2006, 07:13 PM
This is great to see! I am curious as to the strength of such a prop? How would cardboard hold up in a convention where it is likely to get bumped quite often?

You truley have an amazing talent. And judging fom the items on the shelf in the BG a great taste in comic mechandise aswell!

featherweight
02-18-2006, 07:34 PM
with the dowel and the glue it'll hold up nicely to any reasonable use and or bumps at a con

Vicky
02-19-2006, 01:13 PM
frist i would only recomend this style of build to a single edged sword like a katana other swords tend to pose a whole other set of problems i've had to renvent the way i do things for the swords i'm working on now

Yeah, I kinda figured. I'll need to think of someway of making a normal sword then, but this will definately help me. Thanks again, great work!

harokaru
02-19-2006, 09:48 PM
How many sticks of glue do you usually use for this?
(How many is 'lots'?)

Vicky
02-19-2006, 11:40 PM
It sounds like a full package to me, but the glue is pretty cheap.

featherweight
02-20-2006, 06:09 AM
How many sticks of glue do you usually use for this?
(How many is 'lots'?)

the actaul number will be around 80-100 small sticks going rate for sticks tends to be 5cents each so the cost will be 5 or 6 bucks for the glue

Azure
02-20-2006, 12:17 PM
How many layers do you cut into to put the dowel in?

featherweight
02-20-2006, 12:57 PM
right though

ChrowX
02-20-2006, 01:48 PM
I'm kind of curious as to what kind of glue gun you're using. Seeing as you use large amounts of glue ins ome of your projects,a low-heat glue gun couldn't be the most idea.

I'm guessing you're using something more industrial on the larger projects.

featherweight
02-20-2006, 02:32 PM
i have both a large and small gun both are craft modles i've used industrial ones in jobs befor, way too hot for my taste but doing big things with small guns isan't bad i built the buster sword with just a little one so if you don't just happen to have a big one its not like you have to go out and get one just for this kinda project

Atrista
02-20-2006, 03:01 PM
your work is inspiring, I love your gallery. It really makes you realize that you can make just about anything out of cardboard with patience and skill. Fabulous job on everything, and thank you so very much for the tutorial, it will come in very very handy.

LadyAxum
02-20-2006, 09:57 PM
do you have any adivice for making more western style swords where the hilt guard is extends out sideways instead of it being circular like in katanas?

violetsky
02-20-2006, 10:51 PM
yay! this is super-helpful

featherweight
02-21-2006, 09:29 AM
I have now added an expansion pack westren Brodsword tutorial to the start of the thread hope thoose who asked me about it might find it helpful

Legatosgurl
02-21-2006, 09:59 AM
That is so COOL! I'm collecting cardboard for my school anyways (we're making a great wall of china, chibi-ized). Hopefully there will be enough for me to make my sword. *Evil grin*
Thank you SO much for this information!
*bow*

Vicky
02-21-2006, 01:03 PM
what's a broadsword?

featherweight
02-21-2006, 01:12 PM
large dudled edged medieval sword , lord of the rings kinda ones but the tutrail can be used for most dudled edged swords its all about the basic principles used

Atrista
02-21-2006, 09:04 PM
I have a question, on your first example pic, what did you use to color the blade silver? Acrylic silver? It looks so realistic :)

featherweight
02-21-2006, 11:11 PM
yeah it is Acrylic silver paint

Tenshi Musouka
02-22-2006, 11:40 AM
Well, thanks to the TTC's new policies... My Trunks sword is not allowed at Anime North, so I need to make an alternate one that is good for the convention. This sounds like the perfect solution. If it turns out even HALF as good as one of yours, I will be amazed.
I will be sure to PM you with pictures once I have this completed. Thank you for posting the broadsword instructions.

Unknowbie
02-22-2006, 12:21 PM
the actaul number will be around 80-100 small sticks going rate for sticks tends to be 5cents each so the cost will be 5 or 6 bucks for the glue

Where are you getting hot glue at 5 cents a stick?

TenshiKaitou
02-22-2006, 12:31 PM
eh heh heh, though I've put off most of your tutorials so far because I don't know where to get most of the stuff you used from. Example, a dowel?! glue gun...?! lol. BUt, the katana looked too excellent to pass on (drools). Not anymore. I'm going to try too! Do you think I can find such stuff in an art store? Sorry about such silly questions...^__^;;

featherweight
02-22-2006, 01:29 PM
i buy my glue at a doller store called dollarama but if your buying them by the stick from a craft store you might end up paying 10cents a stickst shop around .but right now i'm looking into buying a more ...industrial amount of glue ofr myself just stock pile egounh to last afew years in one buy

dowels will easliy be fond at any hardware store about $1 and glue guns at any crafts store about $4

Baka
02-22-2006, 02:18 PM
Could you just contract someone to help you make the katana... I mean personally I am not very skilled in the kraft of cardboard swordmaking...
-Marco

Vicky
02-22-2006, 11:00 PM
contract someone to help you make it? I'm confused by the question ^^; you want to comission someone to make it for you?

featherweight
02-23-2006, 10:17 AM
a new photoshopped verson of the katana tutorial has replaced the frist one i think its 100% better and my thanks go out to Najica who did an awesome job

Baka
02-23-2006, 12:51 PM
contract someone to help you make it? I'm confused by the question ^^; you want to comission someone to make it for you?

I guess anything would work... If someone could help me make it... or I could even commision someone to make it for me I dont mind either way...
-Marco:toothy:

Vicky
02-23-2006, 02:37 PM
Well I'd over to try it but I've never done it before so I wouldn't have the practice lol I'll be learning by using this wonderful tutorial myself.

Unknowbie
02-23-2006, 05:33 PM
One thing about practicing is the only thing you would be using would be the cardboard, hotglue and time. The cardboard should be free (see dumpster diving), hotglue is cheap at 5-10 cents a stick and time is however much you want to invest. The hardest thing that i can see looks to be painting. Thank god for knowing art majors who will help paint lol ;)

Looks to be broken down like this:

Glue cardboard together
Layer cardboard and glue layers together
Cut out shape
Cut out slot along length of blade to put wood core in.
Layer cardboard on top to hide the core
Fill in areas with Glue that have holes
shape & Paint

Ill take a bunch of photos when i go through this, but it wont be for another week or two. Have a conference to go to next week.

Baka
02-23-2006, 05:41 PM
One thing about practicing is the only thing you would be using would be the cardboard, hotglue and time. The cardboard should be free (see dumpster diving), hotglue is cheap at 5-10 cents a stick and time is however much you want to invest. The hardest thing that i can see looks to be painting. Thank god for knowing art majors who will help paint lol ;)

Looks to be broken down like this:

Glue cardboard together
Layer cardboard and glue layers together
Cut out shape
Cut out slot along length of blade to put wood core in.
Layer cardboard on top to hide the core
Fill in areas with Glue that have holes
shape & Paint

Ill take a bunch of photos when i go through this, but it wont be for another week or two. Have a conference to go to next week.

Koo... Thanks alot and I'll attempt it again... Thanks...
-Marco:toothy:

w00tmonger
03-12-2006, 10:14 PM
just a thought... would these steps work well for cloud and sephiroth swords?

angelstar1088
03-12-2006, 11:06 PM
What kind of paint did you use to paint the blade and the handle of the sword?

Chellian
03-12-2006, 11:27 PM
I am attempting to make elbow blades using your method, and I have a couple of questions (if you don't mind!):

1. How do you get the hot glue so smooth on the edges and sides? My edges were not smooth at all, and I had to resort to taking an old flat iron to smooth them out (which actually worked very well, but took patience). Can you sand the hot glue?

2. What kind of primer do you use? I was looking at some of the guns you made in your gallery, and I was curious as to what has worked for you.

Your work is amazing from just cardboard and glue, and I hope mine turn out half as good as yours! The con I am going to has a strict weapons policy and this seemed like the best method to make my blades from. I will be sure to post a pic of the finished product using your method!

featherweight
03-13-2006, 12:59 AM
What kind of paint did you use to paint the blade and the handle of the sword?

its all acrylique craft paint and sharpies

I am attempting to make elbow blades using your method, and I have a couple of questions (if you don't mind!):

1. How do you get the hot glue so smooth on the edges and sides? My edges were not smooth at all, and I had to resort to taking an old flat iron to smooth them out (which actually worked very well, but took patience). Can you sand the hot glue?

2. What kind of primer do you use? I was looking at some of the guns you made in your gallery, and I was curious as to what has worked for you.

Your work is amazing from just cardboard and glue, and I hope mine turn out half as good as yours! The con I am going to has a strict weapons policy and this seemed like the best method to make my blades from. I will be sure to post a pic of the finished product using your method!


1. patience pretty much does some it up but yes you can snd it but use a high grade and NO power sanding the heat couse will make bad things happen

2. primer i use is just white acrylique piant its just for the paint job

3. i look forword to seeing your work ;)

w00tmonger
03-14-2006, 07:16 PM
k. do to my impatience and lack of hot glue (and the fact that its acting up), Ive tried an alternative to coating the dowel in hot glue. i have put several layers of hot glue along the sides as so theres a cm or 2 holding it into the cardboard. i have then poured white glue into the rest of the gap filling it off and making a straight edge. there are a couple pieces i may have to sand down but whatever.

its alos a possibility that ill add a layer of thin carboard (or possibly carstock) to finish off the sides where the glue was. would this work well. or should i just avoid the extra layer

sorry if Ive desecrated your name via white glue... It was being weird and drying too soon before i could level it (well)... ill probably use hot glue for the edge though. possibly add some metal plating...

edit: i checked back on the glue situation. a fair deal of what i poared into the gap evaporated. Its leaving a really nice finish but im going to have to add abit more. looks it itll sand down nice in a couple places

featherweight
04-01-2006, 12:45 PM
well i finely finish the sword the "BROADSWORD TUTORIAL" is based on
so thiers finely an example picture up


heres the kinda thing it can be applied to
http://images.cosplay.com/showphoto.php?photo=644813
i'll also add it to the top

Aer
04-01-2006, 03:05 PM
Nice job!!! It's always awesome to see people's tutorials using new methods, and this definitely shows good looking work with simple materials.

fightstar
04-01-2006, 04:29 PM
I bow to your L33+ c4Rdboard sk1LLz !!

bag0k
04-01-2006, 07:38 PM
Finally! A tutorial by featherweight! I've been drooling over your props ever since you started posting 'em. Holy cow, I'm so using your tutorial in the future. :D

Razia
04-01-2006, 09:12 PM
just a thought... would these steps work well for cloud and sephiroth swords?I'm wondering that too, about Sephiroth's at least. In the half-finished-sword pic (the one showing the dowel/hot glue technique), that sword is PRETTY long, but still not as long as Sephiroth's.


Awesome tutorials, BTW, Featherweight! I was thinking of getting Wonderflex to make a sword, but I'm on a budget, so I might use your technique, instead ^.^

featherweight
04-02-2006, 03:30 AM
I'm wondering that too, about Sephiroth's at least. In the half-finished-sword pic (the one showing the dowel/hot glue technique), that sword is PRETTY long, but still not as long as Sephiroth's.


Awesome tutorials, BTW, Featherweight! I was thinking of getting Wonderflex to make a sword, but I'm on a budget, so I might use your technique, instead ^.^

well i'd say a Sephiroth sword would be possilbe but it woukd be prety much the limit for this style of build
at that leagth it might get abit of a bend in it whn your holding it up sideways
pm me if you actauly plan to try it and i'll try to think of streathing tips till than

as for clouds sword http://images.cosplay.com/showphoto.php?photo=521019
that one is a similer to the boardsword-t but most of the egde is built with carboard and not glue becuase the size of the sword allowes the space to do it

as for classic buster sword i wouldn't realy recommand using exactly the kanata-t thats just way more glue than you could deal with. Now i do have afew pretty good ideas on how to make one with out going broke from glue but i don't think i shoudl release a tutorail on some i haven't even built so maybe in a mouths or two when i have some extra time i'll build something to try out hte ideas

P.T.
04-02-2006, 08:30 PM
But, we haven't seen anyone else's...until now. Feather-sama, you did say that other's photo's were alright? If not I'll delete them.

Big Shurkien: http://img.photobucket.com/albums/v171/PurpleTiger/Cosplay/AAAA0005.jpg
Couple of Kunai: http://img.photobucket.com/albums/v171/PurpleTiger/Cosplay/AAAA0006.jpg
(Uncomplete) Hughes Dagger: http://img.photobucket.com/albums/v171/PurpleTiger/Cosplay/AAAA0007.jpg

And a few pictures of the Not-a-sword-but-it's-still-cardboard-Automail Work in Progress: http://img.photobucket.com/albums/v171/PurpleTiger/Cosplay/AAAA0008.jpg
http://img.photobucket.com/albums/v171/PurpleTiger/Cosplay/AAAA0004.jpg
http://img.photobucket.com/albums/v171/PurpleTiger/Cosplay/AAAA0003.jpg
http://img.photobucket.com/albums/v171/PurpleTiger/Cosplay/AAAA0002.jpg
http://img.photobucket.com/albums/v171/PurpleTiger/Cosplay/AAAA0001.jpg

Atrista
04-02-2006, 09:08 PM
to prevent bend in a long sword like sepheroiths, you could possibly use a courrugated plastic center. Just a thought. The materials are available at your local sign shop.

featherweight
04-03-2006, 12:47 AM
to prevent bend in a long sword like sepheroiths, you could possibly use a courrugated plastic center. Just a thought. The materials are available at your local sign shop.

hmm it might work but i'd be weary with all the hotglue and glue shaping the thin plastic could melt and distoret pretty easy


i do think i've come up with 2 degiens mods which would would give the stearth boost need for the extra long blade

http://i12.photobucket.com/albums/a241/featherweight-cosplay/longbladetips.jpg
1) for the last last 2/3's of the blade make the gain of the cardboard on the two outer layers run with the lenght of the blade.
(this wil give a stearth boost but would be redonedent on a blade under around 4 feet long)


2) instead of cutting the dowel snap it so you get two frayed ends than useing a wood glue, glue them back togetter on an angel so it can be put in the blade (this one could be use for any sword you wanna add alittle extra stearth to)

doing thoose two things togetter should be enough to sapport a blade fiarly well to about alittle over 5 feet

featherweight
04-03-2006, 01:28 AM
But, we haven't seen anyone else's...until now. Feather-sama, you did say that other's photo's were alright? If not I'll delete them.

Big Shurkien: http://img.photobucket.com/albums/v171/PurpleTiger/Cosplay/AAAA0005.jpg
Couple of Kunai: http://img.photobucket.com/albums/v171/PurpleTiger/Cosplay/AAAA0006.jpg
(Uncomplete) Hughes Dagger: http://img.photobucket.com/albums/v171/PurpleTiger/Cosplay/AAAA0007.jpg

And a few pictures of the Not-a-sword-but-it's-still-cardboard-Automail Work in Progress: http://img.photobucket.com/albums/v171/PurpleTiger/Cosplay/AAAA0008.jpg
http://img.photobucket.com/albums/v171/PurpleTiger/Cosplay/AAAA0004.jpg
http://img.photobucket.com/albums/v171/PurpleTiger/Cosplay/AAAA0003.jpg
http://img.photobucket.com/albums/v171/PurpleTiger/Cosplay/AAAA0002.jpg
http://img.photobucket.com/albums/v171/PurpleTiger/Cosplay/AAAA0001.jpg

other's photo's are prefectly fine
-the big Shurkien i like and form what can seee it doean't really need any notes from me
-the kunai i can still see a good bit of glue lumps on the blade so i'd say just take an exacto knife and cut away any of the razed bumps and maybe alittle sanding other than that they look good
-Hughes Dagger i'm liken' it so fare but for you next project like that you might want to use an exacto knife to cut out the pieces you'll get less bend marks in the board and clearer egdes which will help the over all look
and i'm very pleased you modded my degian in to hughes dagger thats just the kind of stuff i really wanna see

-now the Automail, the structer of it seems to be going fine but your leaving it all abit squar you really shouldn't be afiard to just go at that board and bend the piece till it's nice and curvey and round

keep up the good work PurpleTiger.

P.T.
04-03-2006, 04:37 PM
Alright. *makes notes*

Kunai: As far as good edges with the glue goes, I keep two razor blades. It's easier, for me anyhow, to just smooth the glue out when it's still hot instead of waiting until it cools and getting bad edges. Use the other razor to cut the glue off the other.

Dagger: I tried that. I also cut my finger with it. ._. Good bit of blood.

Automail: It's a bit bulky yes. But I will note that I didn't use a glove for the hand either. (Couldn't find one, so I went without.)

Thanks for your advice!

Chellian
04-03-2006, 06:45 PM
Okay, I have uploaded some pictures of the steps I used for the Loka Luha and Syi Salika (elbow blades) for Talim. I am not finished with them, but have at least finished the blade part of one of them. I pretty much used all of the steps from the broadsword tutorial and improvised when needed. I am pretty impressed with myself, as these will be the first real weapons I have created myself (Mihawk sword doesn't count!).

See the steps in my gallery:

http://images.cosplay.com/gallery.php?cat=38501&member=37299

I have also included a reference pic, but it may not show the blades too well.

Thank you Featherweight, for all of your help!

DarkKefka
04-03-2006, 08:46 PM
I'll be coming to this thread for a minute.

featherweight
04-04-2006, 03:22 AM
Okay, I have uploaded some pictures of the steps I used for the Loka Luha and Syi Salika (elbow blades) for Talim. I am not finished with them, but have at least finished the blade part of one of them. I pretty much used all of the steps from the broadsword tutorial and improvised when needed. I am pretty impressed with myself, as these will be the first real weapons I have created myself (Mihawk sword doesn't count!).

See the steps in my gallery:

http://images.cosplay.com/gallery.php?cat=38501&member=37299

I have also included a reference pic, but it may not show the blades too well.

Thank you Featherweight, for all of your help!

yes yes smashing good stuff very nice smoothness. primer realy does help eh.
keeps it up your going great

Unknowbie
04-04-2006, 11:08 AM
to prevent bend in a long sword like sepheroiths, you could possibly use a courrugated plastic center. Just a thought. The materials are available at your local sign shop.


What a great idea. One of my friends just ran for city council and he has a TON of those signs left.... Looks like i might be borrowing a few of them to make a sword out of lol.... get the cardbard AND plastic.

Personally i hate sanding gesso/primer so im just going to sand it a bit, and then let it go, if you dont sand it too much it looks more "battle worn" :)

Atrista
04-04-2006, 01:01 PM
What a great idea. One of my friends just ran for city council and he has a TON of those signs left.... Looks like i might be borrowing a few of them to make a sword out of lol.... get the cardbard AND plastic.

Yeah, I used them on the center of my weapons for ayame, so I think as long as you use a low heat (aka 'craft') glue gun it's ok. I can't vouch for the super heat industrial ones though, featherweight might be on target when he predicts that could melt it. You could also use another form of adhesive just for that layer then use hot glue on the rest.

To the guy who menioned using a curling iron to smooth the glue, OMG that is brilliant!! I will immediately appropriate one for that purpose. Smoothing the glue has always been my biggest pitfall thus far, and I think this might really work. Once I finish my current FFX Nirvana, I'm going to try to make a cardboard one and I do believe that will help a whole bunch.

Unknowbie
04-06-2006, 01:22 PM
So how well will this work, i want to make a larger sword, but i want the edges to smooth up on both sides, could i put two layers together, then make make another two layers, but cut off like an inch around, and just keep making the layers an inch or so in width less than the one before (would look like stairs). Then take some cardboard and just lay it over the top of the ridges? How well would that idea work?

Also how do you get such detail on the handles of your weapons?

featherweight
04-06-2006, 10:09 PM
So how well will this work, i want to make a larger sword, but i want the edges to smooth up on both sides, could i put two layers together, then make make another two layers, but cut off like an inch around, and just keep making the layers an inch or so in width less than the one before (would look like stairs). Then take some cardboard and just lay it over the top of the ridges? How well would that idea work?

Also how do you get such detail on the handles of your weapons?

well post a pic of what your trying to make about if your tlakn' about whati think your talkign about it would probly work but the best thing you can do is just try if it fails you've only used up some cardbaord

and on the handle thing its a combo of cardbaord comic backs and many many hours

Atrista
04-06-2006, 10:42 PM
Featherweight, I have a question about your keyblade. If you don't mind sharing, how was the crown shaped part at the end of the blade created?

featherweight
04-08-2006, 07:15 AM
Featherweight, I have a question about your keyblade. If you don't mind sharing, how was the crown shaped part at the end of the blade created?

ok ok since so meny people have been asking me about this i will write/draw a kingdom key tutorial and reviel more of my ninja cardboarding secret techniques
(i can always just invent more secret techniques so i don't mind sharing =P)

Atrista
04-09-2006, 09:38 PM
LOL, you truly are the Original Cardboard Ninja Featherweight. I know we all appreciate you sharing with us : ) Thanks so much!

halofire
04-10-2006, 11:40 PM
Inspired featherweight's result AND method I finally found a zanpakutou to fall in love with and a way to realize the dream!

The hilt still needs to be finished and somewhere along the way the blade acquired a slight warp (that you probably won't notice unless you look for it?) but there are shots in my "odds and ends" gallery of the almost-finished product!

I deviated a tad. My hot-glue sculpting skills are below grasshopper novice level, so the cutting edge of the blade is actually paperclay, which was less frustrating.

Followed by two weeks of gesso and sanding about a billion times because white is a very unforgiving "color" to work with.

Thank You Featherweight for sharing! I am one delighted Shinigami.

http://images.cosplay.com/gallery.php?member=32473&cat=31119

fightstar
04-11-2006, 10:32 AM
Inspired featherweight's result AND method I finally found a zanpakutou to fall in love with and a way to realize the dream!

The hilt still needs to be finished and somewhere along the way the blade acquired a slight warp (that you probably won't notice unless you look for it?) but there are shots in my "odds and ends" gallery of the almost-finished product!

I deviated a tad. My hot-glue sculpting skills are below grasshopper novice level, so the cutting edge of the blade is actually paperclay, which was less frustrating.

Followed by two weeks of gesso and sanding about a billion times because white is a very unforgiving "color" to work with.

Thank You Featherweight for sharing! I am one delighted Shinigami.

http://images.cosplay.com/gallery.php?member=32473&cat=31119


Good job. I just cut my cardboard from a couple of Dell monitor boxes and I am starting the glueing process this week some time. That Soul Cutter looks lethal enough to cut a Hollow in half.

Let me give an "Awwwww Snap!" Those Waraji are hella' tight yo! You have to point us to the many tutorials on Waraji weaving so we may follow in your "foot steps", so to speak.

A few questions about the Soul Cutter.

1) what was the thickness of the cardboard you used? There is the thin cardboard that soda can 12 and 24 packs come in. There is the time that fruit and reems of paper are packaged in and there are some thicker than that.

2) What kind of glue gun and size did you use? I have the blue "El Cheapo" version and it melts the little glue sticks. Do we all need something bigger or no?

Thats all I have for now. Thanks for the motivation and if I get anywhere I will post pics. Thanks!

phaedrus
04-11-2006, 10:37 AM
The only problem with cardboard is that it can only be folded so many times, unlike the dozens or hundreds of times you can fold heated metal. Good results with the cardboard, though.

Unknowbie
04-11-2006, 11:04 AM
LOL, you truly are the Original Cardboard Ninja Featherweight. I know we all appreciate you sharing with us : ) Thanks so much!


Now all we need to see is a complete oriential costume made entirely out of cardboard, and leave it unpainted so its still the cardboard brown with a cardboard sword. That would be awsome. Then we have the true cardboard ninja heh

halofire
04-11-2006, 12:50 PM
You have to point us to the many tutorials on Waraji weaving so we may follow in your "foot steps", so to speak.

I'll have to poke through my bookmarks and find the ones I borrowed from, I don't remember if the primary tutorial was one someone here did or if it was just one someone had linked to. I will check!


A few questions about the Soul Cutter.

1) what was the thickness of the cardboard you used? There is the thin cardboard that soda can 12 and 24 packs come in. There is the time that fruit and reems of paper are packaged in and there are some thicker than that.

Standard corrugated cardboard, the kind used for any USPS approved shipping boxes. The blade was three layers thick (a little thicker than I would have liked, but hey I was trading a degree of realism for convenience of materials)


2) What kind of glue gun and size did you use? I have the blue "El Cheapo" version and it melts the little glue sticks. Do we all need something bigger or no?

I used the duel-temp glue gun by Aileen that came in a case with a few different tips for the gun (found at your run of the mill Michaels or A.C. Moore, probably even Wal-Mart). I'm pretty sure those only come in the normal (not mini pea-shooter) size. If you're going to be crafting or costuming, definately a good investment, I use mine all the time! Hotter glue stays workable longer and in my experience the smaller "el cheapo"s cool before I can stick things together! It definately made creating automail SO much better.

Good luck!

featherweight
04-11-2006, 01:35 PM
halofire very nice sword the blade is very well painted and i think its great your chaning up this style of build that whast its here for jsut to give you a palce to start so you can go any were you like with it:bigtu:

Now all we need to see is a complete oriential costume made entirely out of cardboard, and leave it unpainted so its still the cardboard brown with a cardboard sword. That would be awsome. Then we have the true cardboard ninja heh

http://i12.photobucket.com/albums/a241/featherweight-cosplay/cbninjacopy.jpg
that the sort of thing you had in mind ?:skidude2:
ok doodle break over i have to get back to writing/drawing the key blade tutorial

Razia
04-11-2006, 08:42 PM
hmm it might work but i'd be weary with all the hotglue and glue shaping the thin plastic could melt and distoret pretty easy


i do think i've come up with 2 degiens mods which would would give the stearth boost need for the extra long blade

http://i12.photobucket.com/albums/a241/featherweight-cosplay/longbladetips.jpg
1) for the last last 2/3's of the blade make the gain of the cardboard on the two outer layers run with the lenght of the blade.
(this wil give a stearth boost but would be redonedent on a blade under around 4 feet long)


2) instead of cutting the dowel snap it so you get two frayed ends than useing a wood glue, glue them back togetter on an angel so it can be put in the blade (this one could be use for any sword you wanna add alittle extra stearth to)

doing thoose two things togetter should be enough to sapport a blade fiarly well to about alittle over 5 feet
The image won't work ;_;

Thanks for the advice, tho. If it'll work for a blade that's just over 5', that should be fine. I plan on making the sword's length about equal to my height, and I'm about 5'5" (I'll be a female version of Seffie).

Ooh, and my b/f JUST bought a computer desk too *swipes the box, while laughing maniacally*

featherweight
04-11-2006, 08:50 PM
The image won't work ;_;

Thanks for the advice, tho. If it'll work for a blade that's just over 5', that should be fine. I plan on making the sword's length about equal to my height, and I'm about 5'5" (I'll be a female version of Seffie).

heh opps its fixed now

fightstar
04-13-2006, 12:43 PM
After starting down the road to building my first Cardboard Ninja Sword or Ninja-to I would like to find out more about cardboard gaging. In other words different thicknesses of cardboard for different areas or parts of armor or swords.

I will post pics of my progress as soon as I can get a hold of a working camera. I have a few friends on my list who can help so hopefully this week.

The other thing I'd like to know about is cardboard and bondo. I am just in awe over that Ultimate Iron Man Helm you have. I am working on a light helm of my own and was wondering if you have any words of advice for useing bondo on cardboard.

featherweight
04-13-2006, 01:07 PM
After starting down the road to building my first Cardboard Ninja Sword or Ninja-to I would like to find out more about cardboard gaging. In other words different thicknesses of cardboard for different areas or parts of armor or swords.

I will post pics of my progress as soon as I can get a hold of a working camera. I have a few friends on my list who can help so hopefully this week.

The other thing I'd like to know about is cardboard and bondo. I am just in awe over that Ultimate Iron Man Helm you have. I am working on a light helm of my own and was wondering if you have any words of advice for useing bondo on cardboard.

well about the gaging of cardboard i prefer a single corrugat carboard made of a nice thick paper the smoother the better of somethign flat like a sword and i just tryign and find a board the bends well for cruves best thing to do thier is to just test it out and see how the board acts if it wrinkels ,cracks or flods funny . or does it just bend in to a nice cruve than it would be good to make aroumer and things like that

as for the bondoe and cardboard i find the two work well togethor but its best to only use the bondoe to smooth whatevr cruves you want out after just mashing the cardboard in to the shape you want to exacpt it to change the shape alot. Also paint the whole thing even parts you don't see to seal alway the bondo sell which could be bad for you if your wereing it all day at a con if you don't

fightstar
04-13-2006, 05:34 PM
Thanks Featherweight-san *bow*. Thanks for all your help and advice. I will finish sealing my Ninja-to with the hot glue and take some pics before I bondo the sword.

Razia
04-14-2006, 09:11 AM
heh opps its fixed now
Thanks ^.^

Here's another question--will 3 layers and a wooden dowel be enough to support a 5+ feet long blade? Didn't think to ask until I laid out all the squares on my bed (in the position they'll be glued once I get to that point) and realized that they take up almost the whole length of it. XD

I guess that's where the hot glue comes in--probably helps to strengthen the center, eh?

EDIT - Change of length: I've decided to make the ENTIRE sword 5'5" (my height, give or take), and make the handle 15", which leaves about 4'25" for the blade, which doesn't seem so bad =P

featherweight
04-14-2006, 10:39 AM
well my bankai has a blade lenght of 4'4" so you should be fine

w00tastic
04-16-2006, 08:57 PM
I'm just curious, for your Sode No Shirayuki, how did you go about getting the hilt detailing? Cardboard or is there something better that you can use for small detailing such as that? (I'm in the process of making Sode No Shirayuki right now and I got to tell you your tutorial is a godsend!)

featherweight
04-16-2006, 09:35 PM
I'm just curious, for your Sode No Shirayuki, how did you go about getting the hilt detailing? Cardboard or is there something better that you can use for small detailing such as that? (I'm in the process of making Sode No Shirayuki right now and I got to tell you your tutorial is a godsend!)

the hilt on Sode No Shirayuki was just cardboard and hockey tape thier isn't really any too hard detials on that blade

otakuapprentice
04-17-2006, 01:05 AM
is it better to use a low-temp glue or a high-temp glue?

Emerald_Knight
04-17-2006, 03:43 AM
instead of using hot glue would it be possible to use wood filler from home depot?

Unknowbie
04-17-2006, 09:29 AM
http://i12.photobucket.com/albums/a241/featherweight-cosplay/cbninjacopy.jpg
that the sort of thing you had in mind ?

Yeah looks good :)

Now if i didnt have a million and 1 things to do before ACEN id try to throw it together :P

Unknowbie
04-17-2006, 09:31 AM
instead of using hot glue would it be possible to use wood filler from home depot?


I dont think wood filler is made as an adhesive, its just a filler, its not meant to be used to attach two pieces together. If you were going to use it as a filler it would probally work, just depends on how much you are going to use (adds to the weight).

featherweight
04-17-2006, 10:52 AM
is it better to use a low-temp glue or a high-temp glue?
go for the high temp its faster and gives you more time to work with the glue

fightstar
04-17-2006, 11:41 AM
featherweight, check this out!

http://images.cosplay.com/showphoto.php?photo=657677
http://images.cosplay.com/showphoto.php?photo=657675

These are photos of my work following your tutorial. It's my first cardboard sword. I am going to drop some layers of gesso on this bad boy then and some hockey tape to the hilt. After that do some painting and some sharpe action.

The sword is a little rough around some of the edges which I have tryed to smooth out with a cheap curling iron frm 'Wally World'. Take a look and give me advice. Everyone else, PLEASE, do the same. Only your comments can help me grow. Thanks!

featherweight
04-17-2006, 11:52 AM
featherweight, check this out!

http://images.cosplay.com/showphoto.php?photo=657677
http://images.cosplay.com/showphoto.php?photo=657675

These are photos of my work following your tutorial. It's my first cardboard sword. I am going to drop some layers of gesso on this bad boy then and some hockey tape to the hilt. After that do some painting and some sharpe action.

The sword is a little rough around some of the edges which I have tryed to smooth out with a cheap curling iron frm 'Wally World'. Take a look and give me advice. Everyone else, PLEASE, do the same. Only your comments can help me grow. Thanks!

yes nicely and done the smoothing actions you plan to take should finish it off in to a nice little sword my only note will be on your next sword use a sraight
edge when cuting out the blabe you can kinda tell this one was doen free hand but since this is your test sword i'd say it very good

fightstar
04-17-2006, 12:19 PM
Hai Sensei Featherweight! LOL I am already working on a longer Ninja-to as we speak. This next one will be a bit long in the blade and the especially in the hilt. I will look into using a straight edge. I have one but not as long as I would like. Since I don't have a work table I am using a large flattened cardboard box on the floor to do my work. I plan on dedicating myself to some cardboard art work here since it's alot cheaper and kinda' fun. Thanks for you input and sharing your knowledge with us cardboard art n00blets around here.

featherweight
04-17-2006, 12:33 PM
well you don't realy need a long straight egde just cut the frist length than line the ruler up with what you cut about half way the leght of it and cut more and keep doing that till you get done what you need. I also find its lot easyer to frist go over what your about to cut with a shallow cut just a mm or 2 in to it than that gives you a track to cut in to when your doing the deep one

Emerald_Knight
04-17-2006, 04:07 PM
thanks for the info on the wood filler. Either i must have missed it or it's already known, but can hot glue be sanded?

featherweight
04-17-2006, 04:11 PM
thanks for the info on the wood filler. Either i must have missed it or it's already known, but can hot glue be sanded?
it has been asked, a fine sandpaper handsanding works well, no power sanding

Manjou
04-18-2006, 11:22 AM
Hi there, i'm in the process of making 'sister defender' swords for my manji cosplay using this tutorial and it's going pretty well (i won't deny that working with card stresses me out tho ^^; ) I'll post up the pics when iv got them painted.
I was just wondering whether anyone could help me clear up something for another card sword prop that i'm having, er fun trying to figure out ^^
Ok so i'm trying to make yashamarus 'cleaver' from basilisk (see attatched image) and originally i was just going to modify the tutorial to fit and use a larger piece of dowling i bought by mistake. Then i took another look at the picture and noticed how thin the blade is! O_0 it's probably only about as thick as a single sheet of card! So how do brace it with dowel?? I was thinking going out and buying some flat dowel, but would that support it well enough dyu think??

featherweight
04-18-2006, 11:53 AM
well i'd say two layers with a crossed grain wuold be well enough for soemthign that wide and short unless its over about 14 inchs a dowel isn't all the important

Manjou
04-18-2006, 12:09 PM
Well i thought dowel or something might be needed seeing as it gets really thin towards the handle; which means i'll probably snap it or something when i draw it from the sheath <_<;

A thin line of wood inbetween the two layers then? just for some extra support. I think i'm going to have to go to the hardware store again XD

featherweight
04-18-2006, 12:15 PM
do you have any more pic of the blade?

Manjou
04-18-2006, 12:37 PM
Not really, he draws it like once in the anime, then gets killed ^^;

the only other kinda pic iv got of it is in
http://www.geocities.com/spigbebop/images/yashamaru_refs.jpg
but's it's not very detailed (and my friends got the setting for this series, but doesn't have the page with this weapon on *curses*)

Unknowbie
04-18-2006, 02:45 PM
Featherweight, i was thinking, how well do you think a layer of bondo between two layers of cardboard would work, instead of running a wooden dowel through the weapons? or do you think the bondo would not be strong enough for this type of application?

featherweight
04-18-2006, 02:49 PM
honstly i think that would end badly bondo is ment to make somethign thats already stong smooth. one good bump that kinda sword would likey bend and crumble

Chellian
04-18-2006, 04:41 PM
Well i thought dowel or something might be needed seeing as it gets really thin towards the handle; which means i'll probably snap it or something when i draw it from the sheath <_<;

A thin line of wood inbetween the two layers then? just for some extra support. I think i'm going to have to go to the hardware store again XD

Since it is so short, maybe a wooden paint stirrer would work? It may be too wide, but you can shave a little off and still maintain some stability. Just a quick thought!

Dante Rebellion
04-18-2006, 07:06 PM
Would it work for the OUTside of the sword? Not having a whole lotta luck witht eh hot glue but I have tons of bondo lying around.

featherweight
04-18-2006, 07:23 PM
yeah if you just wanna smooth things out on your sword some bondo would work just fine go easy thu alittle does alot and too much might make things heayver than you'd like

Emerald_Knight
04-18-2006, 09:04 PM
instead of using hot glue to fill in the edge of the blade what else can you use? I am also having probelms with the hot glue. would it be possible to use some kind of plaster, putty or mache to fill in the edge of the blade? I do no mind sanding, but hand sanding the hot glue i found so far has been really slow and making more of a liquid mess and i thought.

Sarcasm-hime
04-18-2006, 09:24 PM
Would you mind if I hosted this tutorial on costuming.org (http://costuming.org)? I think it's really useful.

windchomper
04-19-2006, 12:05 PM
Thanks a whole bunch, featherweight.

Getting the gluesticks at Dollerama! When I read that I was like, 'sweet, that's like 2 secs walk away from where I work!'

Anyway, I'll be planning to make at least one using your method for the upcoming Anime North.

I'll post pictures if we don't botch it up.

Get_Backer
04-21-2006, 04:43 AM
I came across this thread last night and I went out this morning and bought all the materials to make a sword. This is my 1st time attempting to make a weapon / prop for a cosplay. I'm pretty happy with the shape, size and the cut but the texture is all wrong. When I was using the glue gun I was having a lot of trouble so I decided to use a saudering gun to even it out.... didn't turn out so good.

http://i9.photobucket.com/albums/a70/Diba420/DSC00105.jpg
http://i9.photobucket.com/albums/a70/Diba420/DSC00103.jpg

I don't want to give up on it quite yet but I somewhat new to cosplay and not sure where to take it from here. Is there some kinda of clay or something I can use to smooth it out and give it the finish of a real sword? I saw someone post something about using bondo. What is bondo and would it work in my situation? Any suggestions would be greatly apprecaited.

fightstar
04-21-2006, 09:17 AM
This glue gun sounds pretty kewl. I don't if a 'Cold Heat Glue Gun' is any good for the massive amounts of glue we use in card board prop making, but I can see it used for fine detail work. I don't know of anyone who has used it, but check it out anyway. http://www.thinkgeek.com/gadgets/tools/8306/?cpg=wnrss

featherweight
04-21-2006, 02:06 PM
I came across this thread last night and I went out this morning and bought all the materials to make a sword. This is my 1st time attempting to make a weapon / prop for a cosplay. I'm pretty happy with the shape, size and the cut but the texture is all wrong. When I was using the glue gun I was having a lot of trouble so I decided to use a saudering gun to even it out.... didn't turn out so good.

http://i9.photobucket.com/albums/a70/Diba420/DSC00105.jpg
http://i9.photobucket.com/albums/a70/Diba420/DSC00103.jpg

I don't want to give up on it quite yet but I somewhat new to cosplay and not sure where to take it from here. Is there some kinda of clay or something I can use to smooth it out and give it the finish of a real sword? I saw someone post something about using bondo. What is bondo and would it work in my situation? Any suggestions would be greatly apprecaited.

well frist i would say just go over it with a knife and cut away any of the uneven or lumpy bits than give it a good sanding and afew oats of paint if that doesn't give you the shape you than i would saggest some thing like gessoe to smooth it out abit more

This glue gun sounds pretty kewl. I don't if a 'Cold Heat Glue Gun' is any good for the massive amounts of glue we use in card board prop making, but I can see it used for fine detail work. I don't know of anyone who has used it, but check it out anyway. http://www.thinkgeek.com/gadgets/tools/8306/?cpg=wnrss

neat gun but the fact thats its a cold tip gun means you can't use the tip to reshape glue, you alsways have to use the ac adater couse 1.5h is not tht long when your working on a projects like theese and 30 bucks plus shipping just for a mini stick gun, i bought a new one yesterday for 3$
so it is cool and probley be handy ofr emgence repairs at a con but for actauly building stuff like this is seems more truble thans its wroth

ps think geek rocks infact http://www.thinkgeek.com/books/humor/7ac5/
check out the Customer Action Shot ;)>

otakuapprentice
04-22-2006, 03:28 AM
i recently made a katana using the tutorial and it turned out pretty good. only problem was i acted like an idiot and swung it in the air and it broke off at the handle when i stopped. two weeks of effort and a stabbed thumb for nothing!

fightstar
04-22-2006, 10:13 AM
i recently made a katana using the tutorial and it turned out pretty good. only problem was i acted like an idiot and swung it in the air and it broke off at the handle when i stopped. two weeks of effort and a stabbed thumb for nothing!

I wouldn't say ALL for nothing. You work on something like a sword or katana and if you don't test it you may never know if your technique of sword making works or not. When I made my Ninja-to and I added the last bit of glue the first thing I did was, yes, swing it in the air. This is a good thing and have no regrets about it. Now, if you swung it and hit someone that is a problem. Head back to the drawling board and do it over. After all what do you think the rest of us are going to be doing? *heads back to work on making a better, longer, and cooler looking Ninja-to*

featherweight
04-22-2006, 12:50 PM
i recently made a katana using the tutorial and it turned out pretty good. only problem was i acted like an idiot and swung it in the air and it broke off at the handle when i stopped. two weeks of effort and a stabbed thumb for nothing!

do you still have the pieces couse honestly depending on were it broke you might be able to put it back togther and be just fine

otakuapprentice
04-23-2006, 12:35 AM
it broke off right where the blade starts on the katana

sora-no-tsubasa
04-23-2006, 03:28 PM
really awesome work~featherweight^^
i'm going to use your tutor ot make one...
but i have a few questions:P...
1.the acrylic paint can't be used outside and i can't find somewhere which might be safe to use it...(maybe an ventilative but airtight room would be better?!..)
2.where can u get the hockey tape~maybe in a craft store too??
i have the hot glue and hot gun which is pretty nice..and i'll try to get the dowel..so the only difficulty is the paint which can make it realistic

DalaiLiam
04-23-2006, 03:58 PM
By hockey tape, I'm pretty sure he means stick wrap. I'm like 75% sure you can find this stuff in walmart in sporting goods somewhere around the hockey sticks(if they have any) if not Tennis racket wrap may work?

janmurphy
04-23-2006, 06:26 PM
I always have problems with acrylic on hotglue, it cracks and peels cause the glue is slightly flexable and the paint isnt. So what kinda of primer do you guys use?

featherweight
04-23-2006, 11:19 PM
really awesome work~featherweight^^
i'm going to use your tutor ot make one...
but i have a few questions:P...
1.the acrylic paint can't be used outside and i can't find somewhere which might be safe to use it...(maybe an ventilative but airtight room would be better?!..)
2.where can u get the hockey tape~maybe in a craft store too??
i have the hot glue and hot gun which is pretty nice..and i'll try to get the dowel..so the only difficulty is the paint which can make it realistic

acrylic craft piant is prefectly safe to use inside it doesn't realy give off any fumes and isn't even toxic so its realy jsut a matter of putting down soem paper to not make a mess and your good to go

I always have problems with acrylic on hotglue, it cracks and peels cause the glue is slightly flexable and the paint isnt. So what kinda of primer do you guys use?

i haven't had as problem with painting the paintingt he glue myself beyond having to let it sit alittle longer so it cures fully becosue the primer i use is just white acrylic carft paint

By hockey tape, I'm pretty sure he means stick wrap. I'm like 75% sure you can find this stuff in walmart in sporting goods somewhere around the hockey sticks(if they have any) if not Tennis racket wrap may work?

tennis wrap wouldn't work its a sticky foam and wouldn't realy look good on a sword (I play alot of tennis)

Legato2471
05-01-2006, 06:45 AM
>_>

<_<

I love you.

-Goes to make Kadaj's Souba-

xpose
05-03-2006, 10:35 PM
hey man, i had to register once i saw your work, outstanding i must say.



Quick question though, in steps 8, 9 do u put a dowel on both sides or is this done on only 1 side? im sorta confused with that part

and in steps 10,11,12 u measure 1/2 inch from the tip of the blade than draw another blade and cut it and peel on both sides, glue it back correct?


thanks for any answers as im new to cosplaying, but am wanting to defiently try and make some swords from bleach that i find amazing.

featherweight
05-03-2006, 11:35 PM
hey man, i had to register once i saw your work, outstanding i must say.



Quick question though, in steps 8, 9 do u put a dowel on both sides or is this done on only 1 side? im sorta confused with that part

and in steps 10,11,12 u measure 1/2 inch from the tip of the blade than draw another blade and cut it and peel on both sides, glue it back correct?


thanks for any answers as im new to cosplaying, but am wanting to defiently try and make some swords from bleach that i find amazing.


step 8,9 the dowel goes in the hole so it in the middle of the blade than you glue fill both sides

10 11 12
you are drawing ont he edge if the blade on both sides than the cut away the outter layers of board were the egde is the you use glue to fill in the egde

xpose
05-07-2006, 01:29 PM
so we need 2 pieces of dowel to insert on both sides and than blue fill both sides?



another question me and my little brother r tryin to make a sword but he was confused as to how deep to cut in order to place the dowel, i told him to cut deep enough to where it doesnt stick out but i thought i would ask you first before we went on ahead with it. Thanks

featherweight
05-07-2006, 08:05 PM
so we need 2 pieces of dowel to insert on both sides and than blue fill both sides?



another question me and my little brother r tryin to make a sword but he was confused as to how deep to cut in order to place the dowel, i told him to cut deep enough to where it doesnt stick out but i thought i would ask you first before we went on ahead with it. Thanks

it is one dowel in the hole in the middle of the blade so you cut all the way thou

xpose
05-08-2006, 01:39 AM
ok thanks, think that clears up all my questions, thanks for all your help

Natchan
05-09-2006, 04:24 PM
This is perfect for my integra sword, thanks a ton! :japan:

klogg
05-09-2006, 08:08 PM
This question kind of depends on the types of weapons created using Feather's technique... whether it be a shuriken or a full katana, any info is great.

What kind of experience have any of you guys had with how durable these weapons are? Sometimes I really wonder if it's too good to be true; cardboard isn't all that strong and I never knew a wooden stick and a hot glue gun could make something seem that tough... I however read that someone's busted after swinging it in the air- that just won't do if you're at a con for a whole weekend...

It would be great to try out this technique, but I'm a little hesitant. I think we've all made something out of cardboard in our lives, and it's always been so flimsy and hard to shape... I guess it just takes patience and a lot of hard, detailed work?

AnimeMGod
05-17-2006, 02:19 AM
hm..i just read through both sword tutorials..im wondering...would it be possible to combine them and make ichigos sword? but not bankai the huge one that is realy thick and black, the second form?

AnimeMGod
05-17-2006, 02:24 AM
This question kind of depends on the types of weapons created using Feather's technique... whether it be a shuriken or a full katana, any info is great.

What kind of experience have any of you guys had with how durable these weapons are? Sometimes I really wonder if it's too good to be true; cardboard isn't all that strong and I never knew a wooden stick and a hot glue gun could make something seem that tough... I however read that someone's busted after swinging it in the air- that just won't do if you're at a con for a whole weekend...

It would be great to try out this technique, but I'm a little hesitant. I think we've all made something out of cardboard in our lives, and it's always been so flimsy and hard to shape... I guess it just takes patience and a lot of hard, detailed work?
well i havent made one my self yet..but he uses 2 layers of cardboard interlaced with glue, so that helps, then he kina makes a locking system with ahving the squares overlap eachother like | : | : |
|=edges of bottom squares, :=edge of overlaying square
that helps aswell, then he adds a dowel so that also helps..also
im guessing here..but you could use thick foam board if ur scared ^_^..hope it helps correct me if im wrong though

Unknowbie
05-17-2006, 02:21 PM
http://images.cosplay.com/showphoto.php?photo=677052

There is some of the stuff ive made out of cardboard :) Got the armor and sword going on, based off some drawings featherweight did!

Ephemerality
05-18-2006, 02:59 PM
Very nice tutorials!

But I was wondering since I'm making Sephiroth's sword...

How would one go about wrapping the handle like a regular katana? ^^

featherweight
05-18-2006, 03:14 PM
Very nice tutorials!

But I was wondering since I'm making Sephiroth's sword...

How would one go about wrapping the handle like a regular katana? ^^

yes i do cheat with my hockey tape trick which looks ok but if you wanna go with something more real if you run a search for katana wraps on this board thiers a few tutrials and things

Ephemerality
05-18-2006, 03:28 PM
Thankies ^^ I didn't know that you used hockey tape, sounds like it would work just as well! I sort of skimmed through your tutorial and caught bits and pieces on how to make your wonderful cardboard katana's. And they really do look very nice!

Unknowbie
05-19-2006, 12:18 AM
This question kind of depends on the types of weapons created using Feather's technique... whether it be a shuriken or a full katana, any info is great.

What kind of experience have any of you guys had with how durable these weapons are? Sometimes I really wonder if it's too good to be true; cardboard isn't all that strong and I never knew a wooden stick and a hot glue gun could make something seem that tough... I however read that someone's busted after swinging it in the air- that just won't do if you're at a con for a whole weekend...

It would be great to try out this technique, but I'm a little hesitant. I think we've all made something out of cardboard in our lives, and it's always been so flimsy and hard to shape... I guess it just takes patience and a lot of hard, detailed work?


Uh i made a nice big sword out of 4 layers of cardboard, carried it around the entire weekend and nothing happend to it.... until there was 250 lbs of weight put on it, aka got uses as a pole to help someone step up.. then it bent in a a section. Granted i didnt cover it all with hotglue and all the cool stuff, so that could of been part of it. If you want to see the sword its this one:

http://images.cosplay.com/showphoto.php?photo=677052

it bent right where the zip tie was at

Wasnt very much time/effort (and no cost $$!) into putting the sword together. Hardest part i had was cutting through 4 or 5 layers of cardboard. At one point in time the end of the weapon had a total of 12 layers of cardboard on it, but it was too top heavy heh.

AnimeMGod
05-20-2006, 02:58 PM
hey quick question...would swuares of 7" by 7" work becouse i found this old black light box in my closet and its frigign long so im thinking it work just fine for a sword, but its width is 7inchs..which i dont think would make a diff but i wanna clear it up with you. oh and its has round 6, 7" groups in it so that makes 40 inch length..so would it work?

P.T.
05-20-2006, 07:03 PM
Since A-Kon's coming up soon, I'm starting work on my Nausicaa sword. I've made a few other swords and whatnot; they've turned out just fine.

But...what do I do about a sheath?

AnimeMGod
05-20-2006, 07:37 PM
Since A-Kon's coming up soon, I'm starting work on my Nausicaa sword. I've made a few other swords and whatnot; they've turned out just fine.

But...what do I do about a sheath?
well u can just use 2 pieces of blade length carboard, bout the thickness of each side with a little bit extra like an inch or so...then fold im down the midle*length wise* and fold em over the blade, like u would do for the handle?, and glue em liek that, then cut out a piece for the bottom, and that bout it..i guess it was a quick thought

P.T.
05-22-2006, 04:34 PM
Yeah. I figured something along those lines, but how sturdy would that be? Something like that wouldn't last too long I'd think.

AnimeMGod
05-22-2006, 08:37 PM
no, no it wouldnt, so u could always reinforce it with a system of dowels lol ehhe i dunno mine isnt gon have a sheeth, too big for it.wel i did somethinking well u know how featherweight does a system of locks? like : | :: | :
:=lower cardboard edges ,|= upper level cardboard edges, well i was thinking you could dot hes ame by designing the flded crap with a line across the sides, then a layer the width of sheeth ontop, one it reinforces the sheeth, two it hides those annoying edges! so that could work also

AnimeMGod
05-29-2006, 09:10 PM
AHA!!! i finally finished my sword after round a weeks work!!
yippeee!!!
here are the pics!
http://img.photobucket.com/albums/v147/AnimeMGod/finished_sword004.jpg
http://img.photobucket.com/albums/v147/AnimeMGod/finished_sword001.jpg
http://img.photobucket.com/albums/v147/AnimeMGod/finished_sword002.jpg
^_^

herr_major_is_i
05-30-2006, 04:05 PM
Haaa! :D I love this concept! i'm working out a 3-d step by step animated instruction version of it for my personal use and my friends, unless you want me to upload it when it's done? I'm very close to working out a sheath idea for you as well. I'm thinking though, if i use the extra thin cardboard i may be able to make this in official thickness, length, and width?

P.T.
05-30-2006, 04:12 PM
Oh! Thanks so much. :D

featherweight
05-30-2006, 04:22 PM
Haaa! :D I love this concept! i'm working out a 3-d step by step animated instruction version of it for my personal use and my friends, unless you want me to upload it when it's done? I'm very close to working out a sheath idea for you as well. I'm thinking though, if i use the extra thin cardboard i may be able to make this in official thickness, length, and width?

i'd be hapy to add a link to i at the top when your done the sheath issue i'll be taking care of in about a mounth when i have to make my next one after its done i'll post a tutorail cuse lots of peoople have asked

as for "official" sizes its best to leave thats kinda thing out becuase since the materails verys so much from soruce to soruce and the fact the theese tutorails are intended to be just to show basic techines the more spasfics you add the harder they become to adpat

Kouen
05-30-2006, 05:38 PM
I'm having some confusion about the edges part and gluing. After you roughly finish the katana, the sharper edge should be blunt. So do you peel off 1 layer of cardboard on each side then fill it with hot glue, and than you sand it?

I'm also finding trouble filling up the corrugated holes with hotglue, when I sand it the glue ontop of the holes get sanded off, and if I don't there will be huge bumps.

featherweight
05-30-2006, 06:16 PM
I'm having some confusion about the edges part and gluing. After you roughly finish the katana, the sharper edge should be blunt. So do you peel off 1 layer of cardboard on each side then fill it with hot glue, and than you sand it?

I'm also finding trouble filling up the corrugated holes with hotglue, when I sand it the glue ontop of the holes get sanded off, and if I don't there will be huge bumps.

yes you got the idea ,
and try putting the tip of the glue gun right to the corrugat holes, glue, than use the eged of the tip of the glue gun to rud the glue in

pearle
05-31-2006, 12:11 PM
I love your tutorial!!! It has given me ideas on how to work on my Caribun~~ Thanks!!!! Good tutorial!!!!

One question to ask though. The carboard, it isn't that easy to bend it into half. How did you do it?

P.T.
05-31-2006, 05:04 PM
i'd be hapy to add a link to i at the top when your done the sheath issue i'll be taking care of in about a mounth when i have to make my next one after its done i'll post a tutorail cuse lots of peoople have asked

A month? oog. A-kon's in two weeks.

AirSong
06-01-2006, 08:38 AM
sorry D: , but since I can't find a translation for dowel n.n;;, can someone explain to me what it is?
thanks!

featherweight
06-01-2006, 11:32 AM
sorry D: , but since I can't find a translation for dowel n.n;;, can someone explain to me what it is?
thanks!


dowel is a pre made wooden rob you can buy at most hardwere stores they come in lots of sizes

http://www.rapideducation.co.uk/i/06070001.jpg

AirSong
06-01-2006, 12:42 PM
thank you very much! n.n

SilverTwilight
06-01-2006, 11:43 PM
I'm also having trouble making edges with the gluegun. I tried using the hot edge and some toothpicks to smooth it out, and it seems to be working, but the outer edge is uneven. Can you actually sand over hot glue, and will it still come out smooth? (I making a broadsword, the sword from Shadow of the Colossus)

Kawaii_Shoujo
06-01-2006, 11:58 PM
AHA!!! i finally finished my sword after round a weeks work!!
yippeee!!!
here are the pics!
http://img.photobucket.com/albums/v147/AnimeMGod/finished_sword004.jpg
http://img.photobucket.com/albums/v147/AnimeMGod/finished_sword001.jpg
http://img.photobucket.com/albums/v147/AnimeMGod/finished_sword002.jpg
^_^

Not too bad, though you would probably have better success with cardboard glue, PVC and Duct Tape. I have a prototype dagger I am working on and it is constructed out of those things. Once I take the time to cut new pieces out to make another one I will take pictures of the process so you can get an idea on how I do it.
This is what it currently looks like but is in no way finished.

http://img91.imageshack.us/img91/6963/rydiasdagger23vg.th.jpg (http://img91.imageshack.us/my.php?image=rydiasdagger23vg.jpg)

Chellian
06-02-2006, 09:16 AM
I'm also having trouble making edges with the gluegun. I tried using the hot edge and some toothpicks to smooth it out, and it seems to be working, but the outer edge is uneven. Can you actually sand over hot glue, and will it still come out smooth? (I making a broadsword, the sword from Shadow of the Colossus)

You can smooth hotglue, but not with a sander. It will sand too fast and the friction will cause the glue to melt and it will get on the sandpaper. You will have to sand it by hand, but it is possible.

featherweight
06-02-2006, 09:06 PM
well this is yet another visaul aid for the tutorail, I've had afew people ask me about the edge step so i posted this http://images.cosplay.com/showphoto.php?photo=703914

pearle
06-02-2006, 11:52 PM
featherweight >> something to ask. there is one tutorial on the sword making, which i think its step 4. you said, cut the middle all the way down, but not till the end.so where do i cut until?

featherweight
06-03-2006, 12:06 AM
featherweight >> something to ask. there is one tutorial on the sword making, which i think its step 4. you said, cut the middle all the way down, but not till the end.so where do i cut until?

i said "cut down the middle of the pieces but not all the way though the board than bend the pieces along that crack"
so you'll get them to be like this
http://s12.photobucket.com/albums/a241/featherweight-cosplay/?action=view&current=DSC06921.jpg
the frist half speaks of the the lenght of the cut the second speaks of the depth

pearle
06-03-2006, 09:09 AM
oh okie~~ thanks for ur help featherweight ^_^

AnimeMGod
06-03-2006, 02:41 PM
well i used wood glue bc the hot glue was hard to work with while just craming the pieces into the pattern, and i used it for like smoothing out the sword bc like i said hotglue cooled to quickly, so yeah ill probably wont make another one because it was just something to do for when i was bored :-P

fuzzydude
06-03-2006, 05:21 PM
Featherweight, I think it was mentioned somewhere in your photo gallery that you also make sheaths out of cardboard and glue. How do you do it?

featherweight
06-08-2006, 12:49 AM
Featherweight, I think it was mentioned somewhere in your photo gallery that you also make sheaths out of cardboard and glue. How do you do it?

fine fine fine ok ok ok i will write a sheath tutorail right now but keep in mind i'm still in the middle of making it so this is still mostly theoretical

eBay Sniper
06-08-2006, 02:09 PM
quick question, can i subsitute hot glue with Gorilla Glue? would that work?

featherweight
06-08-2006, 02:54 PM
quick question, can i subsitute hot glue with Gorilla Glue? would that work?

i've never used gorilla glue so i have no idea so all i can say is try it and find out

Nara Shikamaru
06-08-2006, 03:23 PM
quick question, can i subsitute hot glue with Gorilla Glue? would that work?

That might not work so well because gorilla glue expands. It's worth trying but you might have to sand it or something after because it will probably deform the shape of the blade.

featherweight
06-08-2006, 03:36 PM
-SHEATH TUTORIAL- is done and added to the top of the thread
http://forums.cosplay.com/showthread.php?t=76828 its right after the katana tutorail

eBay Sniper
06-08-2006, 10:45 PM
That might not work so well because gorilla glue expands. It's worth trying but you might have to sand it or something after because it will probably deform the shape of the blade.
thats what i was thinking with the expansion and i dont mind sanding either

otakuapprentice
06-08-2006, 11:52 PM
yo, featherweight. i noticed in your pics that you made cloud's main sword from Advent Children. the question i have is this: do you think its possible to make all of the swords out of cardboard and be able to combine them into one, or would it be easier to just make the complete sword as one giant item? im considering on trying to do this later on.

by the way, your tutorials have been alot of help. i was able to make a thunderseal from the game Guilty Gear out of it, and it looks great. i'll try to get some pictures so i can post them up, and i also made a pair of cerberus guns from Gungrave. i'll try to post those up too.

featherweight
06-09-2006, 12:04 AM
yo, featherweight. i noticed in your pics that you made cloud's main sword from Advent Children. the question i have is this: do you think its possible to make all of the swords out of cardboard and be able to combine them into one, or would it be easier to just make the complete sword as one giant item? im considering on trying to do this later on.

by the way, your tutorials have been alot of help. i was able to make a thunderseal from the game Guilty Gear out of it, and it looks great. i'll try to get some pictures so i can post them up, and i also made a pair of cerberus guns from Gungrave. i'll try to post those up too.

i'd for the one big sword alot less headachs but if you really wanna take of the muilty sword you go right ahead it is possilbe just an epic amuont of work

happy i could be of any help and looking forword to pics

featherweight
06-11-2006, 04:40 PM
http://images.cosplay.com/showphoto.php?photo=711115
that is the frsit sheath built to my new tutorail and it work out rather well all i need to do now is paint

Purple Flames
06-11-2006, 05:07 PM
http://images.cosplay.com/showphoto.php?photo=711115
that is the frsit sheath built to my new tutorail and it work out rather well all i need to do now is paint

Wow that looks great. I'm gonna attempt to make Suzumushi using your tutorial. I have just about everything I need to get started. I just have to go dumpster diving for cardboard =P

herr_major_is_i
06-12-2006, 04:30 PM
i'd be hapy to add a link to i at the top when your done the sheath issue i'll be taking care of in about a mounth when i have to make my next one after its done i'll post a tutorail cuse lots of peoople have asked

as for "official" sizes its best to leave thats kinda thing out becuase since the materails verys so much from soruce to soruce and the fact the theese tutorails are intended to be just to show basic techines the more spasfics you add the harder they become to adpat

ah, i see, thats cool, i'd like to show a pic of what this sword i making in cardboars soon from rurouni kenshin, all the parts were created and placed according to the instructions here. I'm amazed it fit so well in the 3d program :)

featherweight
06-13-2006, 12:47 AM
ah, i see, thats cool, i'd like to show a pic of what this sword i making in cardboars soon from rurouni kenshin, all the parts were created and placed according to the instructions here. I'm amazed it fit so well in the 3d program :)

the 3d looks nice

i just gotta say remeber to make the back of kenshin's sword the egde couse thats why its such a cool sword after all

herr_major_is_i
06-14-2006, 02:44 PM
well, it's not kenshin i'm doin this year, but Yahiko, (samurai X version). i'm using screencaps for reference... (like this sword)

featherweight
06-15-2006, 06:11 PM
http://images.cosplay.com/showphoto.php?photo=718363
thiers the completed sheath that goes with the new tutorail


also
well, it's not kenshin i'm doin this year, but Yahiko, (samurai X version). i'm using screencaps for reference... (like this sword)

looks to be a pretty standard katana shouldn't give you too much truble

R-chan
06-18-2006, 09:59 PM
hmm how hard would it be to do a cardboard sword of X's divine sword
http://www.kurotsubasa.com/X/Fuuma.jpg
And how about a fencer's sword?

featherweight
06-18-2006, 11:03 PM
hmm how hard would it be to do a cardboard sword of X's divine sword
http://www.kurotsubasa.com/X/Fuuma.jpg
And how about a fencer's sword?

well the x's blade is just a thin broad sword and would not be too hard in cardboard the handle thou extremly complex and time consuming is not impossilble for that kinda thing you gotta break it down and friger out what you have to do adn take it on piece by piece and little by little it'll get done

ellax
06-19-2006, 11:41 AM
hi featherweight,

is it possible to make a power ranger helmet out of cardboard?

featherweight
06-19-2006, 12:04 PM
hi featherweight,

is it possible to make a power ranger helmet out of cardboard?

a rounded helmet is possilble
http://images.cosplay.com/showphoto.php?photo=648963

but i'm sure thier are better matrails to use to make a power ranger than cardboard
i have seen many very good power ranger cosplayers i would ask how they made thier helmet befor resorting to cardbaord

ellax
06-19-2006, 11:52 PM
i try to reduce the cost as much as possible.

do you have a tutorial to make a round helmet using cardboard?

thanks in advance..

TB_Iris
06-22-2006, 05:22 AM
Hey Featherweight, is there any chance you'll be making a cardboard shield tutorial sometime? I mean I know you wouldn't be able to set one up before Expo(I'm such a procrastinator), but for future cosplays I'm very curious on how you made your Link shield.

FeelLikeRain
06-22-2006, 05:34 PM
The katana tutorial is seriously awesome, firstly because they look great and secondly because I don't have a lot of money to spend. ^_^;; I'll be making two of them~

Pazuzu
06-22-2006, 10:41 PM
Ohman this makes me SO happy thankyou<3333 I don't have to worry about the hassle and mess of wood now~ (plus I love the glue gun)

And SHEATHYES. YESYESYES. I've been dying trying to figure those out. THANKYOU again, your tutorials really are great :DD (oooh hay mind if I photoshop it together like the initial katana was~?)

featherweight
06-23-2006, 01:34 AM
(oooh hay mind if I photoshop it together like the initial katana was~?)


feel free to

Pazuzu
06-23-2006, 08:59 PM
Done so :D

http://img.photobucket.com/albums/v254/zoozanator/Sheath01.jpg
http://img.photobucket.com/albums/v254/zoozanator/Sheath02.jpg
http://img.photobucket.com/albums/v254/zoozanator/Sheath03.jpg
http://img.photobucket.com/albums/v254/zoozanator/Sheath04.jpg
http://img.photobucket.com/albums/v254/zoozanator/Sheath05.jpg

Beryl
06-24-2006, 08:57 PM
I've got a question. I want my sword to be as smooth as humanly possible, without using Bondo, if at all possible. In other words, even if the glue is 100% flush, the cardboard itself has its own texture that I don't want to show through. Will a few extra coats of paint alleviate this?

I thought about using some kind of sandable primer, which might help make thing smooth, but I dunno. I have no idea how paint (or primer) reacts to cardboard.

Sadakuno
06-24-2006, 11:51 PM
Sorry if I missed someone asking, but would this method be possible to make Renji's Zabimaru from Bleach? I'd imagine the extra thickness and teeth and stuff could cause some trouble.

Beryl
06-30-2006, 03:42 PM
Sorry if I missed someone asking, but would this method be possible to make Renji's Zabimaru from Bleach? I'd imagine the extra thickness and teeth and stuff could cause some trouble.
Now that I've read enough of Bleach to know the sword, I can comment.

I'd guess that you could probably do it, but you'd have to be rather careful with the teeth, as they wouldn't be reinforced at all. It's likely not the ideal sword to make with this method, but it can't hurt to try!

Beryl
07-03-2006, 10:39 AM
Hate to double-post, but what do you guys think about using Gesso (http://www.art-boards.com/Acrylic%20Panel%20Gesso.htm) on something like this? That might be what I'm looking for.

Chaotic_Blue
07-03-2006, 05:46 PM
Hate to double-post, but what do you guys think about using Gesso (http://www.art-boards.com/Acrylic%20Panel%20Gesso.htm) on something like this? That might be what I'm looking for.
Well I've been using Gesso to smooth out the uneven glue/surface of my Suzumushi and it hasnt failed me yet. I'm pretty happy with the results.

Beryl
07-03-2006, 07:40 PM
Well I've been using Gesso to smooth out the uneven glue/surface of my Suzumushi and it hasnt failed me yet. I'm pretty happy with the results.
This (http://www.art-boards.com/Acrylic%20Panel%20Gesso.htm) is the kind of stuff (http://www.dickblick.com/categories/gesso/), I assume.

Any tips or recommendations? Brands?

Also, after browsing the boards some more, I found that some people also use white glue (like Elmer's, sometimes diluted with water) rather than gesso. If we're on the cheap - and we are - that could prove a good solution, too.

Chaotic_Blue
07-03-2006, 09:17 PM
I wasnt able to get mine online so I bought it from our local art store for about 7 or 8 bucks which wasnt too bad price-wise. It had 16 oz and that was enough for me to finish my katana with a little less the half the jar left. I think it was by a company called Pro Art? *runs to check*

I'm not really sure how well the diluted glue works though. Sorry!

Beryl
07-13-2006, 03:38 PM
I made a little dagger-thing to practice my skills before I start on my actual sword, and I learned a few things I thought I'd share.

For those of us that have trouble getting straight lines, what I'd recommend is holding a ruler down and lightly cutting the cardboard with your blade. Then, slowly run your blade along this line, making it a little deeper. You can then use the cut you just made as a guide by inserting the blade into the cut and cutting a little deeper each pass. Alternatively, if you cut all the way through the block at one end of the cut you want to make, you can put your blade in the cut (perpendicular to the blade itself) and rock it back and forth. It tends to work better for me than trying to just shove the blade.

Then again, the block I made was twice as thick as this guide specified, so straight cuts might not be as big a problem as they were for me. :P

Edit - To make this technique easier, you could try (gently!) clamping a yardstick or other straight-edged object to the cardboard, and use it quite literally as a cutting guide, repeatedly running your blade along the edge of the ruler until all three layers have been cut.

FilthyWarumono
07-13-2006, 07:29 PM
<3<3<3<3<3

Now I've just no idea how to make a giant scythe XD;;;;

Beryl
07-13-2006, 11:27 PM
Depending on the style, this could work for you. But in general, I don't think that the Katana method would work well for a giant scythe. The broadsword-style might, but I imagine it'd take a bit of work to make it curve properly. Then again, if you don't need it to curve, that's another story entirely.

FE Freak
07-14-2006, 01:22 AM
I have 3 questions, when you make the 3/8 hole in the cardboard,do you cut all the way through? Or just leave it as a nitch on one side? Also for the guard do you cut 4 layers through the cardboard and then glue or do you peel the first layer off the 'board and then glue?

Beryl
07-14-2006, 07:18 AM
I have 3 questions, when you make the 3/8 hole in the cardboard,do you cut all the way through?
Yes.

Also for the guard do you cut 4 layers through the cardboard and then glue or do you peel the first layer off the 'board and then glue?
For the guard, you cut out four identical shapes and glue them together. Then, fill the sides with glue. After that, you remove a piece from the top and bottom layers, and fill the new edges with glue. Then you cut a square hole in the middle and put it on the sword.

If that doesn't clarify it, I'm not quite sure what you're asking. D:

FE Freak
07-14-2006, 01:47 PM
I figured it out, but doesnt 4 layers seem a little thick? Also what would yall recommend painting wise? I have some chrome aluminum spray paint,would that be convincing enough?

featherweight
07-14-2006, 03:43 PM
I figured it out, but doesnt 4 layers seem a little thick? Also what would yall recommend painting wise? I have some chrome aluminum spray paint,would that be convincing enough?


if 4 layers is too thick for your sword than don't use 4 layers use 3 or 2 whatever you think looks right its realy not important. I can't stress this enough whats done in the tutorial is just and exmaple which is to be changed in any way you need for the sword you want


as for paint i ahave said meny times i like acrylic craft paints myself but if you wanna try something esle go ahead it doesn't hurt to try

FE Freak
07-15-2006, 11:51 AM
Ok,thanks for the tutorial,thank everyone for the help.My sword came out great and i cant wait to show it off at Oni-con.Thank you all again.Actually scratch that..i put too much glue and the sword was too short.I'll try again some other time.

FeelLikeRain
07-20-2006, 06:42 PM
Hopefully this isn't a stupid question, but I'm wondering if one could altogether omit inserting the dowel -- is it just for added strength, or should I definitely include it? I started today on making the swords (I'm making two identical ones), but am still cutting out the 8" x 8" squares at this point. ^^;

featherweight
07-20-2006, 09:09 PM
Hopefully this isn't a stupid question, but I'm wondering if one could altogether omit inserting the dowel -- is it just for added strength, or should I definitely include it? I started today on making the swords (I'm making two identical ones), but am still cutting out the 8" x 8" squares at this point. ^^;

if you leave out the dowel you will heve a very bendy weak katana

FE Freak
07-21-2006, 12:01 AM
Also,you dont have to cut all those squares do you? I just glued together 3 layers of cardboard and went on from there.I also did the 1/2 edge and i didnt get the desired smoothness i wanted.Do you think a 1/2 edge is a little much? I dont mean to criticize i just want to do this right the second time around.

featherweight
07-21-2006, 12:12 AM
Also,you dont have to cut all those squares do you? I just glued together 3 layers of cardboard and went on from there.I also did the 1/2 edge and i didnt get the desired smoothness i wanted.Do you think a 1/2 edge is a little much? I dont mean to criticize i just want to do this right the second time around.

1/2 edge?

Beryl
07-21-2006, 12:22 AM
Also,you dont have to cut all those squares do you? I just glued together 3 layers of cardboard and went on from there.
If you're able to get a flat piece of cardboard long enough, I suppose you don't have to cut it into squares... the squares are easier to glue, though, as you only have an 8"x8" area (at most) to cover with glue. If you had one large piece, you'd be forced to coat the whole thing before sticking them together. And with that much area, you'd need several people gluing at once, or you'll find that your glue will start drying before you're done.

The way the squares are offset might provide a bit more stability by controlling where the layers bend, too but that's just a guess on my part. After you put the dowel in, it really becomes something of a moot point. Most of the strength comes from the dowel, really. And no, don't ever skip the dowel.

I also did the 1/2 edge and i didnt get the desired smoothness i wanted.Do you think a 1/2 edge is a little much? I dont mean to criticize i just want to do this right the second time around.
This guide is just a guideline. A 1/2" blade seems to make a good-looking katana, but if it seems a bit much for you, do as Featherweight suggests: change it!

FE Freak
07-21-2006, 12:24 AM
Will do,sorry for the barrage of questions.

FeelLikeRain
07-21-2006, 08:11 PM
Heh, just as a random comment, I love the "NOW YOU ARE DONE!!!" drawing at the very end of the tutorial. ^_^

So far the swords are coming along quite nicely; I just need the dowels to insert in them. >_> I was looking at your other props, and it is VERY hard to believe that they're just cardboard, glue, etc. Wow.

jrzee
07-23-2006, 07:32 PM
this seems like a very specific question but how well do you (everyone) think that foamcore would work for this? i have a ton laying around but i'm not very sure as to the adaptation from Featherweight's awesome tutorial for cardboard to it. Thanks in advance.

Atrista
07-25-2006, 10:43 PM
I'm nearly halfway done with my sword for Alicia from Valkyrie Profile 2. Made almost entirely of cardboard, dowel rod, and hot glue (there is one peice of wire supporting the crossbar on the hilt). Thanks for all the tips, tutorials and inspiration Featherweight! I still haven't mastered hot glue, but this one has turned out better than my first attempt did.

Picture Here (http://images.cosplay.com/showphoto.php?photo=777268)

I plan to finish it using black leather for the hilt, silver paint, and some small resin casts I made of detail I wanted added to the crossbar. I'll post again with completion pictures.

Link to character art (http://www.hardwired.hu/img/wg/2/878/VALKYRIE_PROFILE_2_SILMERIA_1.jpg)

featherweight
07-25-2006, 11:01 PM
I'm nearly halfway done with my sword for Alicia from Valkyrie Profile 2. Made almost entirely of cardboard, dowel rod, and hot glue (there is one peice of wire supporting the crossbar on the hilt). Thanks for all the tips, tutorials and inspiration Featherweight! I still haven't mastered hot glue, but this one has turned out better than my first attempt did.

Picture Here (http://images.cosplay.com/showphoto.php?photo=777268)

I plan to finish it using black leather for the hilt, silver paint, and some small resin casts I made of detail I wanted added to the crossbar. I'll post again with completion pictures.

Link to character art (http://www.hardwired.hu/img/wg/2/878/VALKYRIE_PROFILE_2_SILMERIA_1.jpg)


yes very nicely doen indeed i look forword to seeign it finished

meepuns
07-29-2006, 04:30 PM
W00t! All hail might featherweight and his awesomeness!

I finally finished my zanpaktou and although it doesn't look nearly as awesome as featherweight, I'm still pretty happy with the results!

I had problems with making the glue smooth after it dried so instead of cutting it off or sanding it (which I both tried), I took a sheet of parchment paper, ya know, that translucent paper stuff you use for cooking, then laid it on top of the glue and ironed it. Ironing it melted the glue underneath which allowed me to take a sharp object and use its edge smooth the glue.
It still wasn't as smooth as I would've liked, so I covered the blade in thin cardboard then used paper mache over it. Still, it didn't look as smooth as I would've like but it was a good alternative for Bondo (at least for me anyways).

Afterwards, I applied a layer of gesso then painted it using metallic acrylics, followed by a gloss varnish to give it that metal-shiny-ness.

For the hilt wrap, or tsukamaki, I used this pic I found through Google: http://pages.prodigy.net/tlbuck/tsuka/katamak1.jpg . It's made of bias tape since I couldn't find any hocky tape in my house. >_<;

I put the process up in my gallery in case anyone wants to see it ^^
http://images.cosplay.com/gallery.php?cat=48258&member=45660

Thanks so much featherweight for being such a cardboard genius and writing this tutorial!

Atrista
07-30-2006, 02:21 PM
Looks nice! I feel your pain on smoothing the glue, I don't seem capable of getting a smooth glue surface no matter what I do...I've come to the conclusion that Featherweight has a deep, mystical conntection with hot glue and is able to command it to do his bidding : )

Great job on the hilt wrapping, the parchment paper idea is interesting.Had I not already painted my blade I might have given that a shot.

AirSong
08-01-2006, 05:00 PM
Ok, I'm confused, I read somewhere you're not supposed, to sand with sandpaper... so what/how do I sand the edge then?

meepuns
08-01-2006, 08:16 PM
@Najica: Hehe thanks ^^ It was my dad who gave me the idea of using parchment paper xD

@AirSong: Hmm.. I'm pretty sure that whoever posted that meant not to sand with those sanders but to do it manually by hand. I'm guessing that sanders are may be too powerful for the glue and also, the sander might cause the glue to melt.

Edit:
Oh wait I found the post that I think you're talking abut..

You can smooth hotglue, but not with a sander. It will sand too fast and the friction will cause the glue to melt and it will get on the sandpaper. You will have to sand it by hand, but it is possible.
Was it that?

featherweight
08-01-2006, 08:41 PM
Ok, I'm confused, I read somewhere you're not supposed, to sand with sandpaper... so what/how do I sand the edge then?


so yes its your not supposed to power sand hotglue, it makes thigns much wrose hand sanding on the other hand can have a fair effect

AirSong
08-01-2006, 09:37 PM
feather:ah ok,
meepuns:yes, that was the post meepuns.

thanks for the help
*is working on tobiume*

Lunnie
08-05-2006, 03:41 AM
Hmmm... I somewhat suspect you of being french featherweight. Anyways, I decided to try out your tutorial and make myself a sword and see how it turns out. It should be finished in a day or two. It's already half done. My hand hurts from cutting so many different pieces of cardboard for the handdle.

Also, I have a few questions.

Do you smooth all of with with cardboard and sand it afterwards or do you use anything else?

And your sand paper, is it a soft grain, medium grain or a hard grain?

Oh and I almost forgot, you use primer before painting right? Do you think something like gesso would do the same?

featherweight
08-05-2006, 04:23 AM
Hmmm... I somewhat suspect you of being french featherweight. Anyways, I decided to try out your tutorial and make myself a sword and see how it turns out. It should be finished in a day or two. It's already half done. My hand hurts from cutting so many different pieces of cardboard for the handdle.

Also, I have a few questions.

Do you smooth all of with with cardboard and sand it afterwards or do you use anything else?

And your sand paper, is it a soft grain, medium grain or a hard grain?

Oh and I almost forgot, you use primer before painting right? Do you think something like gesso would do the same?


nope not french the qwerks you see in my writing are becouse i'm dyslexic not becuose english isn't my frist language.

i do most of the smoothing by cutting away rough bits the sanding is only secondairey and for best results use a meduim grade than a fine


people have used gesso on thier sword befor i hear it works well

Beryl
08-05-2006, 10:15 AM
I'd recommend some kind of smoothing agent, like gesso. Cardboard does have something of a texture, and it will show through when you paint it unless you use bondo/gesso/glue/etc to cover the sword.

Lunnie
08-05-2006, 02:17 PM
Ah yes, dislexcia, hadn't come to mind.

How exactly do you cut the rought bits, with the utility knife or scissors?

And thanks for the tips too.

Marluxia Deux
08-08-2006, 06:53 PM
errr, I'm planning on starting my first cosplay item ever, and I think it will be a katana...I'm going to follow your guide, but I have a few questions..

1:) What hot glue gun would you suggest thats around $15? I'm just a 13 year old kid and my parents are willing to take me around to buy the stuff soo I cant spend alot...

2:) Where would I be able to buy dowels? Would there be any in Lowes or Home Depot?

3:) Will the sword be sturdy enough to play with? (lol I'm stilla kid >.<)

4:) What would you suggest to use to smooth out hot glue?

5:) Do I need to smooth it quickly before it dries?

6:)Would chopsticks be able to replace dowels? Sorry I'm a nub at this

Umm thanks for reading ^^

Beryl
08-08-2006, 11:56 PM
1.) What hot glue gun would you suggest thats around $15? I'm just a 13 year old kid and my parents are willing to take me around to buy the stuff soo I cant spend alot...
Almost anything you find at the store should be okay, though if you can find one, look for a dual-temperature or high-temperature glue gun. That'll give you the most time to work with it. Also, look for something with a large, flat metal nose on it. Mine's really stumpy, and it's really hard to level glue with it.

Make sure you get the right size and temperature glue to match your gun.

2.) Where would I be able to buy dowels? Would there be any in Lowes or Home Depot?
Yes. Also, most craft stores (ie. Joann Fabrics) will carry them.

3.) Will the sword be sturdy enough to play with? (lol I'm stilla kid >.<)
It should, provided you don't hit anything too terribly hard. It's not gonna be a full-contact prop.

4.) What would you suggest to use to smooth out hot glue?
For stuff that's still hot, you can use the tip of the glue gun, or maybe a metal ruler or something... if you need to, you can use a scrap piece of cardboard, but I like the metal ruler because I can easily peel the glue off later and reuse it. Other people have had success in smoothing dried glue with a curling iron.

Use what you've got!

5.) Do I need to smooth it quickly before it dries?
For High-Temp glue, you've got a few minutes to work before it dries fully. If you're prodding it with the tip of your glue gun, you can keep working it even longer. It's not too difficult to smooth it before it dries.

6.)Would chopsticks be able to replace dowels? Sorry I'm a nub at this

Not really. Structurally, you want the longest, strongest, object possible to run through as much of your sword as possible. Chopsticks, no matter how many of them you have, are not going to be able to stand up to a three-foot, nearly-half-inch-thick chunk of wood.

They might work (if you used a LOT of chopsticks really close together), but your sword's quality and durability will suffer drastically.

Marluxia Deux
08-09-2006, 12:36 AM
Thanks ^_^...Well I have these two wood rods...I dont know if their dowels or not. They are wood, and its like rod shaped, its about 2 feet...It's really think in my opinion...Will that work? I cant cant cut them because of the thickness, so can I put two to make a really long blade? And should I make a long handle to support the blade?...Thanks

Beryl
08-09-2006, 12:53 AM
Thanks ^_^...Well I have these two wood rods...I dont know if their dowels or not. They are wood, and its like rod shaped, its about 2 feet...It's really think in my opinion...Will that work? I cant cant cut them because of the thickness, so can I put two to make a really long blade? And should I make a long handle to support the blade?...Thanks
Well, if they're cylindrical and made of wood, it really should matter... as long as they're the right thickness: 3/8".

Using two sections of wood isn't too bad. It should turn out okay. You could make a longer handle, and probably should. The closer to the center of gravity your hands are, the less strain it puts on the sword.

In the end, though, it's your sword, and you should make it how you want it. If something goes wrong, it's only cardboard, and you'll still have the glue gun, so you can try again!

Marluxia Deux
08-09-2006, 01:04 AM
Whats 3/8" mean?....Sorry I'm not good with measuremeents x_x

featherweight
08-09-2006, 02:27 AM
3/8" is the width of the dowel i use dowel comes in meny sizes you see

Beryl
08-09-2006, 10:12 AM
Whats 3/8" mean?....Sorry I'm not good with measuremeents x_x
3/8" is Three Eighth Inches, just a little under a half inch. As featherweight said, it's the diameter of the dowel.

Marluxia Deux
08-09-2006, 01:35 PM
Oh okay....How do I fill in the gap? If I put one dowel so it sticks out on both sides, the gap will have to be perfect to fit the dowel right?

pedicuregirl
08-09-2006, 06:32 PM
awesome tutorial!..so much work! hee

Manveri
08-09-2006, 10:06 PM
Oh okay....How do I fill in the gap? If I put one dowel so it sticks out on both sides, the gap will have to be perfect to fit the dowel right?
You cut the dowel down, so it fits in your cardboard outline. You then fill in the gap between the dowel and the cardboard with hot glue.

I'm almost done with my sword (just have to paint) and I really like how its turned out. Quick, fast, cheap, and good results. Thank you so much for sharing this process!

Emerald_Knight
08-11-2006, 03:30 AM
Can't seem to find it but i am wondering instead of using a wooden dowel rod would it be possible to use a metal rod instead in a 2 layer blade? Also i can't seem to find it right now I must be either be blind or really sleepy but i can't seem to find out here how to cover up the cardbroad rigid texture? any suggetions

Beryl
08-11-2006, 07:59 AM
Can't seem to find it but i am wondering instead of using a wooden dowel rod would it be possible to use a metal rod instead in a 2 layer blade? Also i can't seem to find it right now I must be either be blind or really sleepy but i can't seem to find out here how to cover up the cardbroad rigid texture? any suggetions
Metal might make it heavy, and I don't know how well hot glue sticks to metal, but you're welcome to try it. Just make sure it's absolutely not too big, because if it is, you can't really sand it down to make it flush.

As for removing cardboard texture, you could certainly use the "Search this thread" tool, or Search the boards for something. But since I'm a nice guy, I'll tell you. Popular smoothing agents include: Gesso, Bondo, White Glue, Wood Glue, sandable primer, and/or Epoxy. Results may vary. Do your own research to fin the technique that's right for you.

Marluxia Deux
08-11-2006, 10:36 AM
I think you need 3 layers so its equal on both sides

Beryl
08-11-2006, 11:53 PM
I think you need 3 layers so its equal on both sides
I missed the 2-layer part.

In any case, the middle layer serves as the blade's edge. Taking it out and doing two layers would mess with that, especially when it comes time to actually cut the edge.

It could still work, maybe... but you need to be really careful with it before the rod is inserted, even with three layers. Two layers is going to be really, really fragile until you insert that rod, so watch out.

Marluxia Deux
08-12-2006, 01:59 AM
Wait so with the dowel, I have to cut it so nothing sticks out? So it will have flat sides?...Oh and the paint, what kind of paint should I get to get like a Smooth Silver Shiny blade?

Emerald_Knight
08-12-2006, 03:52 AM
i found that if you use a primer paint 1st and use a ultra fine sand paper to sand the primer paint, and repeat the process another time or 2 then any kind of silver spray paint will have a nicer look. I perfer using model spray paint from testor.

Marluxia Deux
08-12-2006, 08:02 PM
Right now I'm on the step where I have to draw out the blade on the cardboard...But I cant seem to draw a perfect one...Any tips?..And can someone also explain to me the step where I have to put the dowel in? I still dont understand it

Beryl
08-12-2006, 11:42 PM
Right now I'm on the step where I have to draw out the blade on the cardboard...But I cant seem to draw a perfect one...Any tips?..And can someone also explain to me the step where I have to put the dowel in? I still dont understand it
Okay. Here's how it goes, super-simplified.

You draw a box, basically, as long and wide as your dowel(s). If your dowel is 3/8" thick, for example, this box should be 3/8" wide. Should fit like a glove. This box should extend into the handle, and through as much of the blade as possible. Take your knife, and cut this box out, entirely. You will now have a dowel-shaped hole. Cut your dowel to the right size (if necessary), and fit it in there. Cover it with hot glue, smoothing it over to create a flush surface. When it dries, repeat on the other side. Neither dowel nor glue should be above the cardboard's surface, on either side.

Depending on the shape of your blade, your box may not be one straight line (see the tutorial for an example of this).

Got it?

Beryl
08-19-2006, 09:12 PM
Hate to double-post, but I have to add something.

I've been taking my project slowly because I find it to be very frustrating. It's not easy to cut through the hot glue, which often leads to uneven cuts. However, I just got a perfect line (awesome for me) by doing the following:

With your straight line drawn on the cardboard (you used a ruler, right?), extend your super-cutty-thing as far as it goes. Grip the handle with one hand, and place the tip of the blade along the line. Get the blade as low to the cardboard as you can, and look at it from above. The blade should follow the line perfectly. Draw the blade along the line (you may need to press down on the back of the blade to help it cut), trying your best to keep the blade directly over the line.

It's hard to explain without pictures, but the longer you make your knife, the easier it is to see exactly where it's going to cut.

I dunno if this is going to help anybody else, but it's helping me quite a bit, so it can't hurt to mention it here.

UsagiNoSenshi
08-23-2006, 12:13 AM
I have kind of a random question. I'm going to be making a 6 foot katana for a cosplay and I've decided carboard would be best, since i can get a nice thin blade this way. I'm considering covering the cardboard with fiberglass cloth and resin. I assume it would work no problem, but I wanted to see if anyone else has tried doing this?

ichigo112
08-23-2006, 11:39 PM
i think a dowel is like a piece of wood wlel id ont understand wut a dwoel is and where to gfet it from casn anyone help me plz. ir eally wanna make tenso zangetsu for my costume. and ns tutorial

Beryl
08-24-2006, 10:19 AM
i think a dowel is like a piece of wood wlel id ont understand wut a dwoel is and where to gfet it from casn anyone help me plz. ir eally wanna make tenso zangetsu for my costume. and ns tutorial
If you were to look at the tutorial pictures - and you should - you may notice that a dowel is a cylindrical piece of wood. That's it. It's a wooden cylinder, three-eighths-inches (3/8") in diameter. As has been said many, many times in this thread, you can buy these at any hardware store, and most craft stores.

ichigo112
08-24-2006, 10:24 AM
ok thank you very much cuz for halloween i am thinking of being hollow ichigo in bankai mode so i thought all i need to si to make katana from this tutorial and featherweights hollow ichigo mask tutorial.

neocarbunkle
08-27-2006, 09:39 PM
My sword is coming along nicely but I worry even with a few good solid coats of paint its still going to look like cardboard, is there anything I can apply to the sword to give it a new uniform texture. I think I heard to use some wax thing before.

Beryl
08-27-2006, 11:20 PM
My sword is coming along nicely but I worry even with a few good solid coats of paint its still going to look like cardboard, is there anything I can apply to the sword to give it a new uniform texture. I think I heard to use some wax thing before.
Paper mache, wood glue, white glue, bondo, maybe a few coats of gesso... take your pick.

[/broken record]

featherweight
08-29-2006, 03:22 PM
THIERS IS NOW AN FAQ FOR THIS TUTRAIL READ BEFORE ASKING
if not you'll make me angery ... and you wouldn't like me when i'm angery

FAQ ->>>>> http://forums.cosplay.com/showthread.php?t=91386 <<<<<-


faq writen by Beryl , thanks Beryl

otakuapprentice
09-05-2006, 02:52 AM
this question isnt for a katana or sword prop, but it involves cardboard nevertheless, so im gonna put it here...how would you go about making the head of EVA-01 from cardboard? i'm thinking about doing something...

Shouri no Hana
09-27-2006, 09:42 PM
okay...I know it says Katana, but I'm wondering, is it possible to make sabers? I'm looking at making the ZX saber from Rockman ZX.

http://img.photobucket.com/albums/v382/silverbands/concept_zx2.jpg

Well I'm looking more or less at the actual saber bit, I'll end up doing something idiotic for the hilt

Beryl
09-28-2006, 07:33 AM
It won't be translucent, but I think that you could use the Broadsword technique also posted in this thread.

Shouri no Hana
09-28-2006, 09:43 AM
I don't care if it is translucent or not, I just wanted to know if it was possible, I was actually doodling on the conpect art last night, I think know what I'm going to be doing now, alot of layering...

Also, seeing that it is a Rockman Zero/ZX weapon there isn't an actually blade to it (Unless it's Phantom's Shuriken, Levithan's Spear or Zero's recoil series) I'll take a lookat the broadsword section, but I doubt I'll end up cutting edges into it.

Beryl
09-28-2006, 05:49 PM
I don't care if it is translucent or not, I just wanted to know if it was possible, I was actually doodling on the conpect art last night, I think know what I'm going to be doing now, alot of layering...

Also, seeing that it is a Rockman Zero/ZX weapon there isn't an actually blade to it (Unless it's Phantom's Shuriken, Levithan's Spear or Zero's recoil series) I'll take a lookat the broadsword section, but I doubt I'll end up cutting edges into it.
Actually, it might be better to use the original Katana tutorial for that, now that I've thought about it. Mostly because - if I recall - the blade is supposed to be paper-thin, while the Broadsword tutorial mainly applies to thicker blades.

You'd probably have to take the concepts applied in the tutorial and apply them to fit your needs... you may also want to reinforce the lowest part of the blade (that extends past the hilt on either side).

The handle will be a pain to make out of cardboard, though, I think.