My son recently asked me if I could make the Sword of Fire from the Ninjago TV show (and Lego sets). Being the Maker Dad that I am I said:
Sure!... Maybe... Probably
Going and finding the sword in our bin of Legos (or Lego Bricks if you want to be technical) I figured that it would be a fun build to put together for him. It's an easier project, but definitely time consuming.
Want to see how to put one together? Let's Ninjagoooooooooooo!
Step 1: Materials
The materials I used for this build were:
A piece of 2x4
Yep... that's it.
The tools I used for the build: (with affiliate links)
Miter saw - https://amzn.to/2MXuBQq
Scroll saw - https://amzn.to/2Vi84lf
Clamps - https://amzn.to/2XDyJq4
Chisels - https://amzn.to/2tNRs4F
Dremel - https://amzn.to/2tNS769
Micro Sander - https://amzn.to/2KszX46
Gold spray paint - https://amzn.to/2MUDpXg
Clear gloss spray - https://amzn.to/2IV61ub
Step 2: Tracing the Sword
I took a picture of the sword and brought it into Inkscape. I used the pen tool and traced out the outline of the sword, then used the edit path tool and matched the curves of the sword.
I measured my son's hand and figured a good size to fit him, then scaled the outline I created to match.
I printed the outline out, taped it together, then cut it out.
Step 3: Prep a 2x4
*insert a 2x4 Lego brick joke here*
I traced the outline onto a piece of 2x4, then cut it to size. I took it to the scroll saw (a bandsaw would work better but I don't have one). I cut out the outline of the sword, then using the picture again as a reference, I drew all the designs on each side of the sword.
Step 4: Start Carving
Here comes the fun part... and the time consuming part.
I marked out the center of the handle, then drew a circle around the edge of the handle.
Then... carving. Lots and lots of carving.
SIDE NOTE: Carving pine is... terrible. A better option would be any kind of hardwood. Any kind. Pine is just not carving friendly.
Step 5: More Carving
After getting the designs of the blade done, I carved out the dragon face on the handle.
Again... time consuming.
The last part was to carve the designs into the handle.
Step 6: Sand in the Place Where You Live
Is that going to be stuck inside your head now?! You're welcome.
I took a micro sander to sand down the larger flat areas on the sword, especially on the blade, and get the whole thing sanded down.
For the fine details of the sword I took a sander bit on my Dremel and sanded down all the curves and nooks of the dragon's face.
Step 7: Make It Gold
I took some gold spray paint and painted the sword. I added 2 coats to each side, letting them dry inbetween coats.
To finish off I took some gloss clear coat and, again, put 2 coats on each side of the sword. I allowed each coat to fully dry between each coat.
Step 8: Enjoy!
Now that it's done, enjoy! Go fight some evil snake lords, or skeleton armies, or whoever needs a good fight with someone wielding the legendary sword of fire!
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