Black Gold Saw Sword

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:

Materials

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

Tools

1.      Jigsaw

2.      Router

3.      Multifunction powertool

4.      Utility Knife

5.      Glue gun

Procedure

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.