Introduction: Black Gold Saw Sword

About: I am a self proclaimed Junkyard Craftsman. I am an ER Nurse with a love of art, craft and fabrication. I have a habit of looking at things, especially before throwing it away, and thinking "what can I m…

Hello, here I am with a second installation of props for my childrens Cosplay at San Japan Mach 5.  My son went as a male version of a character called Black Gold Saw from the Black Rock Shooter OVA. This character carried a large sword. I present to you my version of this weapon and its build.

Here’s what you will need:


1.Poplar wood8”x 3/4” x 6’

2.Poplar wood6” x 3/8” x 24”

3.Small Styrofoam skull (left over from Halloween)

4.Modge Podge,

5.Wood glue




3.Multifunction powertool

4.Utility Knife

5.Glue gun

Step 1:


1. Draw out the shape of the sword on the 8” x ¾” x 6’ Poplar plank (I kept the total length the height of my cosplayer) and I cut this shape out with my jigsaw.

Step 2:

2.  I used the router with a chamfer bit to shape the blade and saw tooth side andcarved the claw into shape with a utility knife and sanded it smooth

Step 3:

3.  I made 2 tracings of the tsuba (hilt) onto the 6” x 3/8” x 24” poplar plank (including a length of the handle and cut this out with the jigsaw and glued them on each side

Step 4:

4.I planed the Tsuba to shape and routered the outside edges with a rounder bit. I sanded the handle section to blend into the rest of the Tsuka (handle)

5.I rounded the Tsuka to make a more comfortable grip

6.I sanded all rough areas and shaped the edges of the ken where needed to keep it all uniform.

7.I spray painted the claw, Yaiba/Hamon (cutting edge/wave frost), and saw tooth gold and let it dry.

8.I had forgotten about the “scratch marks” on the Ken and so did them at this time with a file

9.I covered the areas I wanted to remain gold with painters tape and spray painted the rest of the weapon black.

Step 5:

10.I put three layers of Modge Podge (letting each layer dry before applying next) on the Styrofoam skull.I then spray painted this Gold once it was totally dry.

Step 6:

11.I drilled two 1/4” holes in the pommel (kashira) and placed segments of a pencil 1” sticking out with a sharpened tip (I had planned to use dowel but forgot to get some and was too lazy on this day to go to the store

Step 7:

12.I pushed the skull on the pencils (keeping it centered) and glued it in place.I took some 2 inch hem tape and wrapped the Tsuka.


Halloween Props Contest

Participated in the
Halloween Props Contest