I made it at TechShop http://www.techshop.ws

When one of your kids ask, "Hey Dad, can you make a Legend of Zelda birthday cake?", the answer is always "Yes", then you figure out a way to do it.

Materials needed:
1/8" x 24" x 10" Acrylic sheet
3/4" x 7" PVC pipe
(1) 3/4" PVC cap
Acrylic solvent cement
Spray paint (gold, silver and blue)
Scrap plywood, particle board, MDF, etc.
Masking or painter's tape
(3) boxes cake mix
water, oil & eggs (per cake mix directions)
(3) or (4) containers of vanilla icing
black food coloring

Tools needed (all available at TechShop):
Laser cutter
Band saw
Miter saw (optional)
Finish sander
Flat file
Vice grips or pliers
Bench vice (optional)
Hot glue gun

Baking hardware
9 x 13 cake pan
bread knife
spatula (for icing)

Step 1: Design of the Master Sword

First off, I've never played, or even seen the video game (nor do I want to), so I did a quick internet search looking for reference images. I found several images, each slightly different than the next, which makes it frustrating when you are trying to copy something. The "Pedestal of Time" seemed to be a very straight forward, angular stone shape, so I focused on finding reference images of the "Master Sword". Again, dozens and dozens of different images, each different than the next. I finally settled on copying this version, since it appeared to be the easiest to duplicate with minimal materials and steps. And since it was really just a decoration for the cake (the stone portion is the actual cake) this image was best suited for the job.

Because the sword was to be inserted in the cake, an all plastic construction was the best way to go. 3/4" PVC was a good choice for the handle, so that is what set the overall scale of the sword. Using CAD (Autodesk Inventor is available to all TechShop members), I started with the dimensions of 3/4" PVC pipe (1.050" OD x 0.824" ID) and just 'eyeballed' the rest of the shapes and dimensions.

Not knowing the size of the stone cake portion yet, I set the length of the blade as long as would fit in the laser cutter. You may download our .DXF file here:  http://www.lime3D.net/instructables/zelda.zip

Cut the pieces on the laser from 1/8" acrylic using the recommended settings.

Tip: Whenever making something from acrylic, and plan on painting it, use clear acrylic. This doesn't make any difference with the painting, but you will have more flexibility to use the scraps for other projects.
This was just featured on the front page today!
Oh I can't wait to see the rest of the photo's! BTW I loved that your answer was yes and then you figured out how to do it! I'm the same way!
Thanks, I made a fixture out of the same acrylic for a biomedical client. They liked it, but then asked if they could get a version in stainless steel. I modified the design accordingly, and then learned how to use the Flowjet water jet and spot weld.
WOWZA!! That is very very cool!!! Do you have any pictures of the steal version?
Not yet. I will be writing an intructable for 'fabricating difficult sheet metal parts' and use the stainless steel fixture as an example. Stay tuned.
I will stay tuned! And I am so glad you let me know you put up more pictures! It turned out amazing!!!
wow this is great!

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