Cosplay Mauritius Props: 2016

I was commissioned to do this weapon from the War frame game.
Sure enough I thought it was easy, well it was not.
This is how the end result look like :

Pretty Slick & pretty big also.( 150 cm in length )

To get there I followed my usual 3 steps process,

Research ( reference picture of person / weapons / fabric)
Material gathering , testing & fitting
Production

1. Research was easy, google provided reference pictures & a simple search gave the pdo file.
For the uninitiated, google pepakura ( 3D converted to 2D ). All I had to do is size the item correctly for the person using it.Simple math, and I got 150cm .
here are the reference pictures.

2. Material gathering was also easy, eva foam, PVC Pipe for the shaft and a NEW MATERIAL.

Alucobond, this thing is light and solid and not flexible, like cardboard but more expensive and more durable. I encountered this material while searching for a replacement for plywood because the form I did broke. Alucobond is one sheet of EVA foam sandwiched by two thin sheets of Aluminum. There's different thinckness and I used the 3 mm.

The technique for making swords, axes, or any long edged , bladed weapon is always the same:

a: a frame

b: a shaft

c. a sandwich

I would do the frame with a hard material ( cardboard, plywood, alucobond etc )

stick it to a shaft ( PVC Pipe ) and sandwich / roll everything with EVA foam.

For this particular weapon, the difficulty was in the bevel edge ( the blade part ) and the embossed/ raised parts.

3. I separated the schindo in 3 parts, the frame, the blades and the shaft. I printed and cutted half the frame and traced it on the Alucubond sheet and mirrored it to get a full frame.