Making props for cosplay or just because can be loads of fun.

In this Instructable, I will show you how to make a the Kingdom Key from the popular Playstation Game Kingdom Hearts.

I personally love to make things and also love video games. These two things have culminated in the me creating a Keyblade.
The methods I am using can be used for making other props and pieces of cosplay as well. It is relatively easy to do, and is also rather inexpensive.

If at any point you are confused, feel free to message me. I would be happy to clarify or help in anyway.

Here is the basic method to make this. This Instructable goes more in depth for each step, breaking it down, and what not.
1. Draw it.
2. Cut it out.
3. Spackle
4. Prime
5. Bondo
6. Paint
7. Varnish
8. Final assembly.

COST: ~$45
TIME: ~7 Days


Rigid Foam Insulation $6 - The link is not actually what I got, but it is basically the same thing. I got 1in x 2ft x 2ft. If you cannot find that, you can always get the 1/2in and double it up. It is in the Building Materials section.

1" PVC Class 200 $1 - They sell it in 10ft pieces, but you only need about 4ft. When you are going to buy it, MAKE SURE THE 3/4" PVC WILL FIT INSIDE. If not you will have to sand down the pipe to fit them together.

3/4" PVC $1 - This is sold in 2ft pieces, get the 2ft pieces

Liquid Nail : Projects $4

Spackle $5 - I already had Spackle, so what I suggest is get the Spackle with the fastest dry time, speeds stuff up quite a bit.)

Various Sandpaper Grits $10

Gesso $8 - Or any foam safe primer. If not, the foam will melt. I didn't use a foam safe primer, I used Kilz. It melted the foam, but it is not that big of a problem if enough Spackle is used

Bondo $11 - This is in the paint section. It is used to fill cracks in automotives, but we are using it to harden and protect the foam. It prevents the foam from snapping in the future. Before you buy this, pull off the white cap and check to make sure there is a tube labeled cream hardener. The hardener is very important.

Disposable Gloves $2

Paint $8- For this, you need Black, Gold, Silver, and Blue. I got Metallic Silver spray paint and a Golden Yellow. I decided to use Acrylic paint for the blue and black since it was only a little bit needed

Varnish $7 - I got Miniwax Polyurethane clear gloss, though depending on what other project you are doing, you may want semi-gloss or satin finish


Saws - Jig and straight
razor blade - Needs to be sharp. Can be taken from a box cutter.
Measuring devices- Yard Stick/Measuring Tape, Ruler
Square/Triangle/90 degree angle
Plastic Spatula (to mix the Bondo)
Popsicle Sticks ( for spreading the Spackle and Bondo)

There are other methods of cutting the foam (such as hot knives and electric wires) and they would work just as well as a razor.

Step 1: Making a drawing of the Keyblade

The first step in this endeavor is to create a stencil of what the keyblade should be. I have created a Google Sketch Up of what the dimensions for everything should be. I actually took paper and taped it together to make a to scale drawing of the Keyblade to get proper dimensions. You don't have to do that, you can probably get away with just drawing the handle and the key.

Then you can use the Google Sketch Up (free for everyone) to plot the the points. I marked various points on the edge the square that when plotted against other points on the adjacent side give the positions of vertices and points. Each point is measured from the nearest corner, except for one side of the Key portion which is measured from the top of the keys box. You can use the tape measure tool in Sketch Up to measure other points if you need to.

I noticed that a handle that fits in a 9in x 9in box is a bit too small. Both hands might not be able to grab hold of the Keyblade once complete. Consider increasing measurements by 10% or so that is better fits you. 

To stencil out the handle, first draw out a 9in x 9in box (this is bigger than standard paper). Then plot all the points. Then connect the dots. 

To stencil out the Key, draw a 7in x 5" box. Then plot all the points. (The shaft is not part of this box). Then connect the dots. 

Quick notes, a small amount of knowledge regarding Geometry is required to to do this. It is not complicated stuff, but just kinda logical things like proofs and knowing that if the edge of the circle is touching a certain point, then then the distance from that point to the center is the radius. 
Also, some of the plotted points may not meet up exactly, but they should be very close. 

Nice! Straightforward and pretty easy, too :)! Love this series so much

About This Instructable


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Bio: Currently in Highschool. When not doing school, I fill my spare time with (in order of importance) making stuff, wood turning, cooking, or playing video ... More »
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