Please take a look at my blog as well for other tutorials: http://quitefranklybuilds.blogspot.com/
Step 1: Cut Out the Handle Guards
I used a jigsaw to cut out the guards. Then I put the template on top of 2 layers and cleaned them up with a flush trim bit. I waited to glue the layers together until after this in case I messed up.
Step 2: Shape the Handle Guard
Next, I turned some discs for the raised bands on the handle guards which are just below the rainguard and at the very bottom of the key. I drilled holes in the smaller discs with the same paddle bit as above. I'll wait till later to glue these on.
Step 3: Making the Main Poles/Blades
I turned the posts on my lather down to 2 inches diameter, and added in some details like the rainguard, the 2 grooves just above the rainguard, and lowered the handle down to 1.5 inches diameter.
Next, I used my Sorby Spiralling tool to add in a spiral texture going in either direction on the handle to get a diamond texture grip, also known as a knurling to metalworkers.
After the poles were finished, I cut notches in them to fit together where they cross to make a halved joint. They won't be glued together just yet, though.
Step 4: Make the Keyblade Teeth
I drilled holes into the backs of the teeth to fit them onto the poles using dowel rods.
Step 5: Fusing the Guards
I placed the poles and discs on the handle guards where they needed to be, and applied bondo to fill in the gap left from the cut and also applied to the notches in the poles to smooth it out. I needed to wait to put bondo the poles together until the guard was set so nothing was misaligned. The bondo is then sanded down and the extra details are added into the guard like lines and the recessed circles.
Step 6: Cutting and Applying the Filigrees and Sword
Next, I cut out the sword design out of 3/4 inch pine with the extra wood edge and cut out the slot for it in the top of the keyblade.
I glued and applied bondo to the areas around the slots to fill in the area and hold in the pieces.
Step 7: Sanding
Metallic paint really brings out bumps in props, so I added even more bondo and sanded. I did this process a total of 6 times before I got a finish I was happy with.
Step 8: Painting
I covered up everywhere around the handle and rainguard and sprayed gloss black on the handle, and an anodized blue paint* on the rainguard. Then everything else was covered except for the handle guard, and that was sprayed with an anodized yellow paint.
*Anodized paint from Duplicolor's line of MetalCast paints work as a transparent spray paint. When sprayed over flat white, it looks like a flat version of that color paint. But when sprayed over silver or silver chrome, it looks like metallic paint.
Step 9: Finished!
Specs: 75 1/4 inches long; about 3 ft wide; 3 inches at thickest; 15 pounds (top-heaviness makes it feel like 30)
The keychain was made by making two 2.5 inch long keyblades, making a recess in the heart shape, gluing, bondo, sanding, and painting. Straight steel chain 10 was used with 2 snap hooks.