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Unread 09-30-2012, 04:17 AM   #1
Takaaaa
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FFVII AC Cloud Strife's Fusion Sword Build (picture heavy)

Just going to make this thread to show my Cloud's fusion sword build.
This is just a build thread and not a tutorial, so it wont be step by step or super detailed. but if you have any questions about parts or things I did, feel free to ask and Ill be happy to help you out. But also if I get stuck and need help, maybe someone can help me out. lol


[Edit]
So someone requested a materials list. I will add it here and update it as I progress through this build.

Hot wire cutter:
Guitar wire (two thinnest strings, which are the E & B string)
Project Enclosure
25.2v, 2 amp transformer
120v Neon Lamp
Fuse Holder
250 volt, 2 amp Fuses
Dimmer Switch
AC power cord

Sword:
2"x96"x48" Insulation Foam sheet
Scrap wood
Hand saw
Wire Hanger
Gorilla Glue
Paint brushes 2" and 3"
KILZ2 primer
Wood (inner support)
Dupli-Color Filler Primer
Different Grit Sandpaper (50,100,220,300)


So let start!

So first I took a million screen shots of the sword from Advent Children. Then opened up photoshop and was able to accurately get the measurements using some math and other techniques. Once I got all the measurements, I went out and bought the supplies. My supply list was pretty short. Pretty much just Pink, well in Hawaii, it's blue insulation foam.
Huge sheet wouldnt fit in my car so I had to use my company car.



Now since 90% of this sword will be made out of this foam, I needed something to use to cut it. Now some people just cut it with a knife and sand it smooth. That's perfectly fine but not only did I want very sharp, accurate edges, but also it will be A LOT faster.

So I made this foam cutter that plugs into the wall outlet. There are tons of tuts on youtube on how to do this. And I swear, it made my life a dream!
all the material cost me about $40 at radio shack and $10 worth of guitar wire



Im actually an engineer so this was right up my ally~




Last edited by Takaaaa : 10-15-2012 at 08:48 PM.
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Unread 09-30-2012, 03:16 PM   #2
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So this is what my hot wire cutter looks like. The red light tells me when its on and the dimmer witch let me control the temperature.



First thing I did was trace out the pattern on my 2" thick foam board. First I cut out the shape so I cut some wood to make a hot wire jigsaw







Done!



Now time to cut these 2" thick pieces in half so I have four 1" thick pieces. time to make a horizontal hot wire station

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Unread 10-01-2012, 04:39 PM   #3
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So today I made edge cute to my blades. By slightly adjusting my cutting station, I now can control the angle of the cut.





The finished product with the blade edge!





Will update more soon~
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Unread 10-01-2012, 04:51 PM   #4
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Today I also cut out the two smaller swords. I also cut them at angles to make the blade edge.



Here are all the blades completed and ready to be sanded and touched up
There are two of each blade because Im going to sandwich them together. Also the smaller blades are half the thickness of the other two so I had to cut them in half and in half once more to get the right thickness, that's why there are four of them. haha

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Unread 10-01-2012, 04:53 PM   #5
rj_sosongco
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Awesome progress, your cuts are looking incredibly clean!
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Unread 10-01-2012, 04:56 PM   #6
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One more update for Oct 1. I just started to sand them down and touch them up today before I have to go to work.

But first I cut out the serrated edges by heating up a bent coat hanger with candles and melting it away.





Then its time to sand!



My hand was very very jittery when I cut this. HAHAHA too much coffee.



But after sanding~ smooth as a baby's bottom~



This is what is done so far~



I will update more later~
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Unread 10-01-2012, 04:57 PM   #7
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Quote:
Awesome progress, your cuts are looking incredibly clean!
Thank you so much for the kind words! The hot wire cutter made my life sooooo much easier. lol
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Unread 10-01-2012, 05:18 PM   #8
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Are you making them where the swords are gonna be glued together for good?
Or are you making then detachable? If you are making them all just to be the big sword and never come apart then you are making it look really good, if it's the other, then you are donne run into some problems..
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Last edited by JasonTerror : 10-01-2012 at 05:20 PM.
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Unread 10-01-2012, 05:23 PM   #9
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That wire cutter is pretty slick
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Unread 10-01-2012, 08:01 PM   #10
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Quote:
Are you making them where the swords are gonna be glued together for good?
Or are you making then detachable? If you are making them all just to be the big sword and never come apart then you are making it look really good, if it's the other, then you are donne run into some problems..
No, they will not be detachable but painted separately and permanently affixed together.
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Unread 10-03-2012, 11:04 PM   #11
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I was pretty busy yesterday and was unable to work on this all day but today I had a bit of time so I made the handles and the curved piece. It was pretty painless and only took me about an hour for everything.

Cutting out the curved piece and smaller sword handles was straight forward and easiest to cut out.





Next was the handles for the two serrated swords on the top. This was a bit more tricky but still straight forward. Just cut out the pieces and then sanded a rounded top before cutting it in half to make two identical handles.







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Unread 10-03-2012, 11:09 PM   #12
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This is what is completed so far. Still have to sand some pieces but just test fitting for now.



I will be sanding and begin adding the inner support and tsuba (or blade guard). I hope to start sealing/priming pieces this weekend.
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Unread 10-03-2012, 11:49 PM   #13
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Oh wow this is awesome! Looks like I can try this as i need to make this but I'm not good at math or cant draw a straight line lol. Keep up the good work also a material list would be awesome
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Unread 10-04-2012, 12:19 AM   #14
JasonTerror
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Wholy bajebus dude!! That's wicked so far..Oh yea love the N64 in the older posts btw lol
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Unread 10-04-2012, 03:49 AM   #15
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Very nicely done!!
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