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 wood 8”x 3/4” x 6’
2. Poplar wood 6” 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
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Procedure1. 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.
2. I used the router with a chamfer bit to shape the blade and saw tooth side and carved the claw into shape with a utility knife and sanded it smooth
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
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.
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.
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
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.
And there you are BLACK GOLDSAW READY FOR BATTLE!
Participated in the
Halloween Props Contest