TMNT Raphael's Sais

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Intro: TMNT Raphael's Sais

No one kicks more butt than the Teenage Mutant Ninja Turtles. Although there are four of them, everyone has a favorite. If his suiting up as the TMNT this Halloween or convention season, don't forget your character's signature weapon. Create Raphael's Sais with the help of this tutorial by Wholesale Halloween Costumes.

Step 1: Supplies

  • 2 – 1/2” x 5.5” pipe insulation tubing
  • Cardboard
  • Metallic silver spray paint
  • Crayola white model magic
  • Scissors
  • Marker
  • Craft knife
  • Sai template

Step 2: Create the Blade

Download, print and cut out the template. Trace the template on the cardboard. Cut out the cardboard blade.

Insert the long end of the cardboard blade into one end of the pipe insulation.

Start by adding small pieces of model magic to the cardboard blade. Apply the model magic in a thin layer, that wraps around both sides of the cardboard. Finish wrapping the entire blade in the model magic. Tip– you can use leftover pieces of cardboard to press down and smooth out the model magic to remove any finger marks. Let the model magic dry for a few hours.

After the model magic has dried, spray the blade silver, and let dry. To achieve a shinier look, I found I needed 2 coats of spray paint. The first layer of paint was absorbed into the model magic and dried matte.

Wrap the sai handle in tan duct tape. For a cleaner look, I applied my duct tape vertically, in 3 long pieces.

Step 3: Make the Details

Cut a piece of grey duct tape (approximately 8” long), and fold in half lengthwise. The tape should stick to itself.

Cut the folded duct tape in half, lengthwise, to create 2 long skinny strips. Step 9. Repeat steps 7-8 so that you end up with 4 long skinny pieces of folded tape.

Step 4: Add the Details

Tape one end of a piece of folded duct tape, to the top of the sai's handle. Wrap the folded tape around the handle at an angle, and tape at the base, as shown.

Rotate the handle, and wrap the second piece of folded duct tape around the handle, as shown.

Repeat these steps, applying the tape in the opposite direction. When complete the tape will create a woven look on the handle.

Cover the bottom of the handle with a piece of silver duct tape. Wrap a ½ “ strip of silver duct tape around the base and the top of the handle for a finished look.

Complete the set of sais by repeating the above steps to create a second sai.

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