Well, I skipped posting a step in between the last post and now, but it's not that important. My dad buffed and sanded the sword down to make it all smooth and then put on three or four coats of primer.
For the sheath, we decided to use matboard, which is kinda like really hard cardboard. It is used in framing a lot. We measured out the length of the sword and built a mock to get the sizing correct and figure out how to not have it collapse. By cutting only halfway through a layer with a razorblade it makes the matboard pliable enough to bend but still retain strength. We bent the side pieces so that they overlapped each other, adding more strength. To add the 3-D effect down the top of the sword, we cut another piece of matboard and peaked it (like a roof). Then we glued in spacers of matboard and a little piece of wood to give it the height that we wanted.
We then covered the entire sheath in packing tape which added strength. Here is a close up of the nose, which was a pain to make.
The sword next to the sheath.
Since the sheath was covered in tape, we put brown paper (like butcher paper) over the entire sheath. We used vacuumount spray to attach it.
Big jump again! To get the doughnut around the handle, we ended up using modeling clay and just shaping the doughnut on around the sword handle. We then let it dry next to heat for a day. We used the same modeling clay for the ridges that are shown in this picture. It's really hard making matching ridges so all the wings look the same! These were glued straight onto the wood with E-6000.
The sword has now been spray painted silver to color the blade. We put on a couple coats of spray paint to make the blade shiny. However, I'm not sure, but I think these leads to increased scuffing if you are not careful with the sword. I already have a couple scuffs from taking it in and out of the sheath since the sheath is a bit of a tight fit.
The only thing left is to wrap the green/yellow string around the blue leather grip on the handle.
|Back view of Sheath and Sword|
If anyone wante more detailed pictures of the sheath I will be happy to send them!
Email me at my cosplay.com account.