Excalibur Corrupting

Hello fellow nerds of the Type-Moon Universe!

Your reading this because you probably need a sword for your cosplay! Hopefully, this will be off assistance.

1. 3D Modelling software (TinkerCAD suffices, however use whatever is available)
2. 3D Printer (Ender 3 or Better/Bigger. 0.8 nozzle if possible, however 0.4 works)
3. PLA Filament (Any brand)
4. Plaster
5. Metal Rod/s (Could be replaced by metal chopsticks)
6. Strong Adhesive (Could be superglue or Epoxy. If plastic welder is available then parts could be Welded Together)
7. Sandpaper (200-400 PP)
8. Spray Paint Primer (Any Color)
9. Paint (Black and Red)

These are the 3D modeled files of the several parts of the Sword, and the source material for the sword. The 3D modeled files were 3D modeled bit by bit. It would both take too long and the explanation being incomplete as the majority of the sword was 3D modeled in sleep deprived delirium.

However, what I can do is instead give to you my STL files directly for your usage.

STL Files Github

Using Ultimaker Cura, open the STL files and modify the dimensions of the sword to your body's dimensions. The sword was customized for a 5''6 person. Make it shorter and bigger through percent changes to the dimensions.

Modify the print settings to be as durable or fast as possible, personally, printing at 70 mm/s, having a constant infill of 20% and a layer height of 0.4 mm was optimal as it was as fast as the printer could go, without sacrificing durability.

Additionally, if possible try to print the sword vertically. This minimizes supports and hastens printing time.

After 3d printing is done, here comes the tricky part. Sand the sword pieces down, so that they fit as best as they could.

Prepare your Plaster by mixing the dust with water at a 1:1 ratio

Get ready your Adhesive and your Metal Rods.

First the guard, apply adhesive to both pieces of the guard and assemble together. Wait for a few minutes, up to an hour, for it to settle.

Going from the ground up, insert plaster into the hole in the handle/grip. Insert the metal rod before the plaster has been set.

Apply adhesive to both the guard and the handle. Then spike the Guard with the exposed part of the metal rod through the hole. Fill in the rest of the hole with plaster. Fill in the rest of the space, and displace the plaster, with more metal rods.

Do this on repeat until the sword has been fully assembled: apply adhesive to area around the hole, spike metal rod through the hole, fill in with plaster, displace plaster with more metal rods until it fills the hole completely.

Firstly, scratch the entire sword with sandpaper so that the paint primer may adhere to the surface of the sword.

Find a secluded place for painting. (Ideally with open air)

Spread something on the ground, so that the bare ground won't be painted as well.

Spray paint it with the paint primer. Flip it after 30 mins, the spray paint it with more paint primer. Remember to apply an even coat.

After the paint primer is dry, Paint it black with red accents.

After painting, the project is done!

Enjoy your sword! Just to be safe, hold it with 2 hands and remember not to swing it at other people!