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Unread 02-17-2006, 06:10 PM   #1
featherweight
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Cardboard Katana -101- (tutorial)

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/a2.../ck-101-01.jpg
http://i12.photobucket.com/albums/a2...0v2/ck01v2.jpg
http://i12.photobucket.com/albums/a2...0v2/ck02v2.jpg
http://i12.photobucket.com/albums/a2...0v2/ck03v2.jpg
* http://images.cosplay.com/showphoto.php?photo=631505 *
http://i12.photobucket.com/albums/a2...0v2/ck04v2.jpg
http://i12.photobucket.com/albums/a2...0v2/ck05v2.jpg
http://i12.photobucket.com/albums/a2...0v2/ck06v2.jpg
http://i12.photobucket.com/albums/a2...0v2/ck07v2.jpg
http://i12.photobucket.com/albums/a2...0v2/ck08v2.jpg
http://i12.photobucket.com/albums/a2.../ck-101-10.jpg

*long blade tips update* http://i12.photobucket.com/albums/a2...gbladetips.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...38#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/a2...y/Sheath01.jpg
http://i12.photobucket.com/albums/a2...y/Sheath02.jpg
http://i12.photobucket.com/albums/a2...y/Sheath03.jpg
http://i12.photobucket.com/albums/a2...y/Sheath04.jpg
http://i12.photobucket.com/albums/a2...y/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/a2...play/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/a2...play/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/a2...play/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/a2...play/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/a2...play/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/a2...play/bst06.jpg

ok heres the links to my other tutorials too
kunai/Shurkien thread
http://forums.cosplay.com/showthread...=featherweight
automail thread
http://forums.cosplay.com/showthread...=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...=featherweight

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

Last edited by featherweight : 09-13-2007 at 07:29 AM.
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Unread 02-17-2006, 07:39 PM   #2
fightstar
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*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*
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Unread 02-17-2006, 07:46 PM   #3
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COOL ^_____^!...That's better than bringing my iaito >>;...
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Unread 02-17-2006, 07:56 PM   #4
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keep the faith!
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Unread 02-17-2006, 08:26 PM   #5
Vicky
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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 ^^;;
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Unread 02-17-2006, 08:56 PM   #6
Master1080
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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?
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Unread 02-17-2006, 09:08 PM   #7
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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.
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Unread 02-18-2006, 12:08 AM   #8
shiro.youma
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I can't get over what you are able to do with cardboard.
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Unread 02-18-2006, 01:07 AM   #9
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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.
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Unread 02-18-2006, 05:01 AM   #10
featherweight
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Quote:
Originally Posted by Vicky
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/a2.../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/a2...y/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

Last edited by featherweight : 02-18-2006 at 08:46 AM.
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Unread 02-18-2006, 11:17 AM   #11
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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!
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Unread 02-18-2006, 12:13 PM   #12
Vicky
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Quote:
Originally Posted by featherweight
http://i12.photobucket.com/albums/a2.../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/a2...y/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
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Unread 02-18-2006, 12:23 PM   #13
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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.
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Unread 02-18-2006, 03:01 PM   #14
featherweight
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Quote:
Originally Posted by Vicky
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
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Unread 02-18-2006, 07:13 PM   #15
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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!
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