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.
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):
Miter saw (optional)
Vice grips or pliers
Bench vice (optional)
Hot glue gun
spatula (for icing)
Step 1: Design of the Master Sword
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.