My Daughter challenged me for a prop for a character she was cosplaying as in San Japan :3 in San Antonio, Texas 2010. She was cosplaying as Shana who is armed with a flaming Katana. I didn't want to make a typical paper mache or wooden prop with flames painted on and an actual flaming prop was out of the question. LED lights then came to mind but the idea of resistors and imbedding the lights into the prop without them looking like Christmas lights was leaving a bad taste in my mouth. An idea using plexiglass, acrylics, and my strobe flashlight then came to mind. So from challenge to brain storming to blue print to construction I present to you my instructible.
Step 1: Materials
These are the materials you will need:
1) A sheet of plexi glass 1/4 inch thick and 3 feet long. You can get away with a using a shorter peice (cheaper this way) and cutting peices you canconnect together to make 3 feet, but this weakens the integrity of the blade.
2) Clear transparent acrylic plates (orange, yellow, and/or red). The flatter the plates the better. These will be used to mimic the shape of flames. I shopped the local dollar stores and found what I needed, otherwise you can find these at Walmart.
3) 1 inch PVC pipe and a cap. You will need about 9-12 inches of pipe, depending on the size of your flash light.
4) I have a Mag Lite XL100, costs about $35. If you have a Mini Mag you can buy their IQ switch and LED light conversion to turn it into a strobe flashlight (this would be cheaper even if you bought a brand new Mini Mag).
5) PVC pipe cutter or hacksaw
6) Coping saw or scroll saw
7) Small spring clams
8) Liquid Nail Perfect Glue 2 or similar glue (Super glue does not work very well)
9) Dremel (if you have one) is always handy in any project
Step 2: The Blade
Step 3: The Flames
Step 4: The Handle
Step 5: Putting It All Together
Step 6: Flame On!
Once all the glue is cured and peices are secure, place your flashlight lense first into the handle followed by your PVC end cap. You can wrap your handle with cord or shoelace to add an aesthetic look. You now have a flaming sword.