Instructables
Picture of Black Gold Saw Sword

Hello, here I am with a second installation of props for my childrens Cosplay at San Japan Mach 5.  My son went as a male version of a character called Black Gold Saw from the Black Rock Shooter OVA. This character carried a large sword. I present to you my version of this weapon and its build.

Here’s what you will need:

Materials

1.      Poplar wood  8”x 3/4” x 6’

2.      Poplar wood  6” x 3/8” x 24”

3.      Small Styrofoam skull (left over from Halloween)

4.      Modge Podge,

5.      Wood glue

Tools

1.      Jigsaw

2.      Router

3.      Multifunction powertool

4.      Utility Knife

5.      Glue gun

 

 
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Step 1:

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Procedure

1. Draw out the shape of the sword on the 8” x ¾” x 6’ Poplar plank (I kept the total length the height of my cosplayer) and I cut this shape out with my jigsaw.                                                                          

Step 2:

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2.  I used the router with a chamfer bit to shape the blade and saw tooth side and  carved the claw into shape with a utility knife and sanded it smooth

Step 3:

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3.  I made 2 tracings of the tsuba (hilt) onto the 6” x 3/8” x 24” poplar plank (including a length of the handle and cut this out with the jigsaw and glued them on each side

Step 4:

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4.      I planed the Tsuba to shape and routered the outside edges with a rounder bit. I sanded the handle section to blend into the rest of the Tsuka (handle)

5.      I rounded the Tsuka to make a more comfortable grip

6.      I sanded all rough areas and shaped the edges of the ken where needed to keep it all uniform.

7.      I spray painted the claw, Yaiba/Hamon (cutting edge/wave frost), and saw tooth gold and let it dry.

8.      I had forgotten about the “scratch marks” on the Ken and so did them at this time with a file

9.      I covered the areas I wanted to remain gold with painters tape and spray painted the rest of the weapon black.                                                       

croberson71 month ago
This is awesome! In the process of making it.. is each of the teeth two inches or three inches?
Dadime (author)  croberson726 days ago
Thank you. They have about a 3 inch base and 1 1/2 inch height.
rhayes81 year ago
Would Black Rock Shooter's sword follow the basic same guide as this? Or could you show how you did BRS sword because I have trouble trying to find good pics or tutorials of it.
Dadime (author)  rhayes81 year ago
I recently posted the build of my version of Black rock Shooters Sword. Enjoy and good luck.
Dadime (author)  rhayes81 year ago
Yes, I can do that. I am currently working on 4 Cosplays due in augustso I will try to get to it. Keep a look out for the instructable.
Nice costume, very...feminine. Had to say it, great sword though. :D
Dadime (author)  16lundgcodm1 year ago
Well, considering its derived from a female character, it was hard for it not to be. Thank you.
Very nice. How heavy is it?
Dadime (author)  jessyratfink1 year ago
Thank you. It is about 3 lbs.