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Picture of Sword Art Online: Elucidator Prop Sword!
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I have been making props for over a year and a half now and I was recently commissioned by my friend to make the Elucidator from Sword Art Online. This was a fun commission for me to do and I want to share how I made it and how you can make one yourself!

This build is relatively easy, even for beginners and only requires a couple of basic power tools which are widely accessible to most people. (chances are you already have the power tools needed in your household) This entire build was made only with hand tools, but if you have access to big tools, (like a band saw, or a drill press) take advantage of using them.

This build uses a layering process as opposed to a solid piece being carved; this means that layers are applied to build thickness. This process is a great way to build lots of different kind of props because it means that symmetry is maintained and accuracy for detail is easier to control.

This build took me about 30 hours from start to finish over the course of 2 weeks so don't expect to make a decent prop if you rush it! Take your time on this build and the pay off will be much better.

 
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First off awesome build! I'm putting a price list together right now. But I'm having trouble finding MDF that is 1-1.5mm thick. Any other suggestions? Also I noticed your wrote 0.80-0.100 inches. This is incorrect as 0.100 is 1/10 and .080 is 8/10 or 4/5 which is almost an inch. It should be written as 0.080-0.100 (or simply 0.08-0.1). Just a little math problem for you. Even though I live in USA and use imperial measurements daily, I find it stupid and prefer metric... Anyway! This is an amazing build and I can't wait to finish it. Thanks for the instructable.
JoshuaGuess (author)  flinjager12310 days ago

Thanks for letting me know; I'm surprised no one noticed it before now. I actually got it wrong completely, 1mm is 0.04 and 1.5mm is 0.06 (I believe so anyway) and I've updated it. As for finding the MDF, model shops are your best bet as thin MDF can be used for model making. I got my stuff from here. http://modelshop.co.uk/Shop/Item/MDF-sheet-500-x-1000mm/ITM7014

Do you think I could make this out of foamboard? I'd have to work around though, since the only foamboard I have is 4.7 mm thick.

JoshuaGuess (author)  Jharmainyack.1 month ago
I don't see why not, although obviously it won't be as strong as wood. I guess if you layered the foamboard 3 times, (making it 14.1 mm thick) you can use an x-acto or utility knife with a steel ruler and bevel the blade and the curved areas; that's just one way of approaching it anyway.

How big is this In Real Life

JoshuaGuess (author)  garrett.ward.96552 months ago

The full length from the tip of the blade to the pommel is 110cm/43.3 inches; Step 2 on this Instructable shows the measurements on the blueprints.

Duuuude this thing is awesome +1 well done
seamster7 months ago

Nice sword! I looks awesome.

JoshuaGuess (author)  seamster7 months ago

Thanks!

can you make these two for around 100$ and minus the fancy on the sword if you can ill see with my parents
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JoshuaGuess (author)  mcroner2 months ago

I'm afraid I'm not able to do outside commissions, what with my college study and my part time job, I'm simply not able to invest the time needed to make these items.

oops forgot to tell you i want it with wood
LarryM13 months ago

I just started watching SAO; I got recommended to watch it, and in the anime, its a heavy sword, i'm thinking of making it as my one-handed training weapon, and adding a metal weight in the center of the blade might act as a strengthener and make it more like Kirito's blade, so, what is this swords weight?

mcroner LarryM12 months ago
actual sword would be 72\3 pounds
JoshuaGuess (author)  LarryM13 months ago

Well I can't say for certain how heavy it was because I do not own it any more, but it was fairly light and it could be wielded fairly easily. If you want to use this for training, I wouldn't recommend making it out of MDF, instead I would recommend a hardwood like red oak or poplar and carve it to shape; this also means you won't need to use a metal weight to support the length. Hope this helps.

Thanks for the info, I actually have been carving a red oak plank, cheaper, and it is looking really great, I'll flash a pic of finished product.

PrashantaN3 months ago

what is the width of the blade?

trying to make slighty variated version of this so it does not take up as much material.

bjohnsen13 months ago

What was the width of the blade?

JoshuaGuess (author)  bjohnsen13 months ago

Imperial is 1.66 inches (or 1 2/3 of an inch). Metric is 4.20 cm

l.a.g.team5015 months ago

how did you print the template?

JoshuaGuess (author)  l.a.g.team5015 months ago

Well in my case, I had access to a massive printer so I could just print it in one go. It's unlikely that people have access to a massive printer so in your case (and most others), you'll need to print the image in sections and join them together with tape once the sheets are printed out.

Alternatively, you could go to a printing shop and pay them to print out the image on a USB stick at full size; that's the only other solution I can think of.

tvrox235 months ago
Why did you use MDF and is there another material that could be used instead?
JoshuaGuess (author)  tvrox235 months ago

MDF is simply the material that I wanted to use because it's cheap and I like working with it. You can use other materials that you prefer, such as PVC sheet or other kinds of wood; it's really down to what material you like working with and what tools you have on hand to use.

riverswamp6 months ago

how long did it take for you to make this?

JoshuaGuess (author)  riverswamp6 months ago

This took about 2 weeks; a few hours every day and that excludes planning time. If you do make one for Dragon con in the future, I would love to see

nice Will do.

riverswamp6 months ago

looks great I want to do this cosplay next year for Dragon con.

den.chew.37 months ago

Looks amazing!

... but I'm curious, how did you make sure you'd get a nice strait drill when you drilled out the hole in the wooden dowel for the handle?

JoshuaGuess (author)  den.chew.37 months ago

That's a good question you've provided. Without a drill press handy (which I didn't) it's quite tricky to get it straight. I tend to have a good eye for drilling straight, plus my drill had the added benefit of having a spirit level built in, which shows when the drill is straight. The only options you have is mark the centre by drawing 2 lines across the handle and mark the area where the 2 lines cross, or have a drill handy that it set at a 90 degree angle.

Robokidd_007 months ago
I'm a huge Sao fan...good job!!
hinagiku7 months ago
I LOVE SAO :O good job :)))
NutBros7 months ago

great..................................................................................................................................

watchmeflyy7 months ago

Looks great!

RandyPerson7 months ago

If your pipe is a little too tight on the dowel, that's perfect. Use a heat gun (no, I actually didn't say a torch would work if you're really careful) and heavy gloves to gradually heat the plastic pipe until it becomes pliable, but still retains shape. Blow the hot air through the center as well as on the outside for even heating. When it's pliable, it will also have expanded just a little. After doing a test fit with a small piece to make sure it will work, slip the warm, soft, expanded pipe over the wood dowel. Have a good mark or stop in place so you can get it right the first time. As it cools, you'll get a clean, glueless joint that will never loosen.

JoshuaGuess (author)  RandyPerson7 months ago

Thanks for the tip! A tighter fit is definitely better than a looser fit. I did consider using my heat gun for the same reason, but I wanted this instructable to have tools that are easily accessible, and I don't consider a heat gun as a regular tool that everyone has.