UPDATE:Added more pictures describing how the pieces are made and such, the second and third links are those. Don't use the HTML version for the time being, I must update that one and it will probably occur sometime this week.
Dittoís Wood Buster Sword Tutorial
So you want to make a buster sword? This one was made for a costume but could also be made to just sit in your room and look cool. First you need plans, right? Right, so let use my original plans with measures and all.
All the measurements in the plans are to a 1:1 scale, so this will make you a life-sized buster sword! Now if youíre reading this and thinking ďthis is going to be heavyĒ DO NOT STOP READING! I promise it wonít be too heavy.
Letís start off by getting all your materials and tools. If you want to follow this tutorial closely then these are the tools you need:
Air compressor + nail gun (or just an independent nail gun)
Saw (various different types will work, as long as it works for what you need Ė look at tutorial)
Wood (plenty, pine will probably work best)
Ply wood (like 2 of those big sheets at the hardware store, make sure they are not broken!)
Gorilla Glue (recommended!)
Wood Glue (any, Elmerís is good)
Elmerís White School Glue
Fabric (I used white, I suggest it since it has no dye in it)
A couple of long, thin, wooden dowels
On big dowel (for the handle)
Nails for nail gun
Sand paper (both for the sander and just some sheet sand paper)
Wood Filler (like the white wood filler)
Water (hopefully you donít have to buy this)
A roll of large brown craft paper (or some other large paper you can draw the whole blade on)
I have no idea how much this all costs, so itís really your choice as to what brand and every thing you use. Now that you have plans and (hopefully) your materials itís time to draw out the whole blade of the brown craft paper. Measure it all out and then draw supports about 10in apart, maybe a little bit less. This is where you will put wood supports on the inside of the sword. One you have all that measured out and drawn then take your wood and cut it out in measures, one for the big long back and various for the supports. Now on the big long piece for the back draw on the point and cut that out with the saw.
Once you are done with that, sand it down a little bit. Take one of the small pieces and make them to a point from where you want it to slant down into a blade (take a look at the plans if you are doing it to scale). After you draw that on it cut it with the saw and sand it down.
Well now we have one support finished! Well then, pull out your carpenterís pencils and put that on another piece and draw the lines you used on it too, keep on doing this so you have a whole bunch ready to cut.
http://cri-cri.net/ditto/bustersword/3.jpg http://cri-cri.net/ditto/bustersword/4.jpg http://cri-cri.net/ditto/bustersword/5.jpg
Now the problem is that the supports turned out like mineÖ. Meaning they arenít equal. We have to fix this. Take all the supports, line them up by the part that they go to point. After that take the saw and even out the other ends (hopefully you made them a bit longer anyways). Now take the power sander and sand down the points to make them even.
http://cri-cri.net/ditto/bustersword/6.jpg http://cri-cri.net/ditto/bustersword/7.jpg http://cri-cri.net/ditto/bustersword/8.jpg
Take one more support and at the back end you are going to cut it to a point, on the skinny side. This one will go near the tip to support the plywood up there.
Now that you have all that done then you can sand them down so they are nice. Now take the back and the supports, you are about to put them together. Take the gorilla glue and follow the instructions on the container and glue the supports in intervals on the back, take the nail gun (probably connected to an air compressor) make sure that the pressure is not too high since that will just go through the wood. It would be a smart idea to test it out a scrap piece of the same wood. Once you get it right then you should put them together. That is quite enough work for one day, and you need to let this dry for AT LEAST 4 hours, but you should let it sit a full 24. If you still want to do more work or you have come back after a day then youíre ready for the hand guard and handle. Take some large pieces of wood (if youíre lucky like me they should just bee sitting near where you do all of your work and you wonít have to buy them). Mark the center; this is where you are going to drill the hole. Now use a bit that is a bit bigger then the large dowel you are using as a handle. Drill them through both
http://cri-cri.net/ditto/bustersword/10.jpg http://cri-cri.net/ditto/bustersword/11.jpg http://cri-cri.net/ditto/bustersword/12.jpg
Go ahead and glue them in place, clamp them and take the handle, cover the part of the handle that will be inside the sword with some gorilla glue, not too much but enough. Now put in the handle and cut it off a bit longer then you need it for the sword, at least that is what I suggest.
Now go ahead and let that dry over night. You can move on to a different part but leave that part dry, you should now have a nice looking drying frame.
Now the drawing of the sword on that craft paper will come in very handy. Put it on the ply wood and start transferring the design, donít dispose of the paper or damage it, you will need it for the other side. I do, however, suggest cutting it into parts so itís easier to cut the opposite side.
Sand down the edges of the plywood, we need to prepare it for when you apply it. Take some of the expanding foam and get the two small pieces for the ending part that is the blade. Get the two pieces to stay together with a nice little rig by gluing it, after that take a little bit of the expanding foam and put it inside, since this part doesnít have much support this will support it a bit better. Take a look at the support I have set up in the picture.
So then the next day you can continue working on the sword. You should start by securing the handle a little bit better. You will drill some holes to put screws in. you will have to remember about the materia slots, mine is slightly inaccurate since I put the materia slots off to the side a little bit and then handle in the middle. You can choose how to do it, but keep the materia slots in mind when you put the screws in. now that you have the screws in and the frame is dry you can start adding different parts to the frame. Start with the hand guard; take some small pieces of wood (you should have some left over from when you cut the supports. Increase the size of the hand guard a little bit with the wood and glue. Let that sit ad clamp it, you can do other things but be mindful of that hand guard.
Now we need to prep the large ply wood pieces to get them on the frame. Sand the edges and then take the fabric and white glue. Line up the two larger pieces of wood how they should be and then water down some white glue a bit and cover the fabric in it. Put it in between the two pieces of the wood so that they connect. While itís still wet (make sure it stays on though) put some glue on the supports, back, and that big piece of wood so you can put the big pieces of the plywood on. After you put it on nail it in place with the nail gun. Turn it over and do the same thing to the other side. Now take your wood filler and fill all the holes where you put nails, fill all the little parts that you need to and you can also put some on the buster sword to make the transition between the two pieces of plywood look a bit better (after painting of course). You now should put the final medium pieces on the ends just like the others, you should have a nice buster sword shape that looks (and is!) almost done.
http://cri-cri.net/ditto/bustersword/19.jpg http://cri-cri.net/ditto/bustersword/20.jpg http://cri-cri.net/ditto/bustersword/21.jpg