Here is sword that is relatively safe as it's foam, cheap to make, and light weight.
You need a hobby blade, a hot glue gun, and a solder iron. A rotary tool would also be useful.
You need a hobby blade, a hot glue gun, and a solder iron. A rotary tool would also be useful.
I am using the Elder Scrolls Daedra sword as inspiration.
I started with 3/8" eva foam mats. I scaled the sword
to 36" overall as it 'felt' right to me. I printed a full size pattern and began cutting.
Due to the size limitations of the foam mats, I had to make a break in the pattern. I broke it just above the
grip, as the hilt will have additional pieces that cover the seam. I
traced the pattern with a hobby blade. I performed an initial cut, and then a second to cut through the
foam completely.
You need to change the blades often. Once they dull, the cuts will be jagged. When sharp, the blade should easily slice through the foam.
The blade is two pieces thick, the hilt four, the handle two, and the pommel is four, though sanded down.
For the grip, I added 1/8" pieces of foam achieve the right thickness.
For the shape of the sword, I've used a hobby knife, a wood burning iron (a solder iron would also work), and a rotary tool.
Be careful not to take too much foam away too quickly. This is my current progress. I still need to shape the sword, but I will write the rest of the tutorial in case you make it farther than me. I've lost interest on this project and am excited for new projects.
Once the sword has been shaped and carved, it's time to paint.
I use Plasti-dip rubber coating. This provides a smooth, yet flexible finish that will stop the foam from absorbing paint later in the process.
I used a number of different gray spray paints for the blade to achieve a mottled, metal look. I began with a black base and layered silvers and grays- going darker to lighter. I used a scuff pad, sanding in only one direction to remove the top layers of paint at edges and to give the blade a striated metal look. I used silver acrylic to highlight the sharp blade edges using a dry brush technique.
The handle is much the same, I started with a dark gray base and a dark wash to accentuate the recesses and add a layer of grime.
Once your colors are done, clear coat the sword.
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