I can't for the life of me find one so I made one..Remember this is not the sturdiest prop. It's only foam. Do not hit things with it..It can break..Also try not to swing it around a lot..You can swing it in a chop style motion without it breaking but if you swing it where the air will hit the sides, it may snap on you. If you want it super sturdy use fiberglass. This tutorial is not using that but you can after my second to last step if that's what you want to do.
-Pink Insulation Foam Board (Mine was 8'x2')
-Cutting too; (I used a seratted knife but I recommend a hot wire cutter)
-Gesso (White goopy kind. Mine's a 16oz jar)
-Liquid Nails Glue In The Tube
-Baking or Air Dry Clay (Mine is an off brand at Michael's that has 2 times as much as scuply for the same price)
-White Foam Board (The kind at Wal*Mart that is foam with paper on both sides)
-Sponge brush (mines a 2", but get whatever)
-2.5in (diamiter) cookie cutter (I used a coke glass but cookie cutters are easier)
-Hand sanding tool sand sand paper (150grit should do it)
-1" wide Wooden dowel
-Paint (Color depends on your choice)
-1.5in width Ace bandage if you are doing the KH version (use 5 dollar store ones)
1. Start out with your foam board, and draw up what you want it to look like. I already has a paper version of the sword I used as a stencil. The size will depens on your height and what you feel is the right size. Mine from the bottom of the handguard to the top of the blade is 51in, and a width of 11.5in. If you have a stencil you should draw it on both sides of the board so you know you can make the cuts straight. Also be sure to indicate on the drawing where the bevel will start. You will see on mine I have lines drawn up it where the blade would start beveling to a point. It will look like this:
2. Cut out the shape..I don't know how to be clearer then that..It will look like:
3. Now is where the fun begins. Start out by making a line down the center on the thickness that indicates how far the bevel will stop at a a point. This is the "striking edge". It looks like:
Then once you do that start cutting away at the foam at an angle. You should be cutting like this:
You won't get all the edge cutting it once in the same place. You need to do a lot. It took me roughly 2 hours to finish both sides. When you are done it will have this torn to shreds look to it like so:
Sanding fixes this. See the saw the blade is facing you in the pic? Face it just like that to you and sand going in front of you pulling it. Don't pus, it snags and rips MORE. This will take a few hours to look nice as smooth. It won't ALL be smooth but this will be fixed later. Here's how it will look:
4. After that you will move on, to the handguard. Now this is prettu easy at first. Just cut a rectangle 12.5in wide by 3.5in tall like so:
Then make a line all the around the thickness on the halfway mark like so:
Then cut it along the lines until it's in half. Shave off until they are only 1/4in thick each and glue them on. It will look like this:
After that drys, Fill in the gaps on either side (bladed and non bladed sides) with extra pieces cut to fit (this will take some time to get the pieces to fit..But here's how mnie looks:
You can fill it with really anything since it will get covered anyway..
5. Then time for the little details. Cut 4 stips of the white foam board that are 12.5in long and 3/4in wide. Then 4 more the same width but only 2in long. Glue the longer ones on both sides like so:
Then do the same with the smaller ones on the 2 sides (bladed and non bladed sides):
Now before we make the rest of this, we need to cut out the holes which should be drawn on your foam. Use the cookie cutter to cut the holes out. You may need to heat it up to make it a little easier, but it's ok not to. Here's the pic of mine with the coke glass:
Next make a hole at the halfway mart on the bottom of the entire thing and DO NOT make it the right size to fit the dowel. Make it smaller, like 1/2in or so. Then sharpen the dowel (again the length of the dowel is whatever you choose) then once it is sharp enough (doesn't need to be a point at all) push it in as best you can and as straight. Don't go TOO far or it;; poke through the holes you made (materia slots). Then, once it's at your desired farness, take it out and slather with glue and shove right back in and hold it for about 2-5min to let it stick to it. then cut out 2 circles out of the white foam board that are about 2in thick with a hole in the center to make it fit over the dowel snuggly. Then glue into place. These are the area right under the handguard that appear to be where the handle was fitted to. Then do the same again but with 1.75in circles that fit snuggly and glue. It will look like this:
Next we need to make the dome details that run along the handguard. Make them out of any baking clay or air dry clay. I recomment sculpy type stuff ) but you can use anything really. Glue them on and it should look a little like this (Do one side at a time though and let it completely dry before glueing the other side. They will be too heavy to stay on until dry):
6. After everything is dry GESSO THE CRAP OUT OF IT!!!! Use the sponge brush to apply it. It will look like this with the first 2 coats or so (Do about 5-6 coats):
Do this over everything but the wood. After that sand and paint. I don't have a finished picture yet as I'm still on the gesso part but yea. This is where at the top I say you can fiberglass it. After gesso you can use resins or fiberglass on top to give it a stong cover and it'll be harder to break. Once I get mine done I will show you a picture on here.
I hope everyone likes this tutorial and can use it to make their own sword. This is also a good tutorial to make other big swords like the one from Naruto or something. Enjoy and happy cosplaying!!
FINAL PRODUCT PICTURE #1
FINAL PRODUCT PICTURE #2
If you are doing the kh version, use the ace bandage and sew a few together to make it longer (I used 5) and just wrap it up starting from the bottom going up then back down and tie it at the bottom so some can hang off.