cubseidl props: Cloud Strife's The First Tsurugi (Fusion Sword)

So I was commissioned to make Cloud Strife's Fusion Sword formally known as the The First Tsurugi.

The Client Specified that he would like this done as accurately as possible but in the combined form only. After some research I found out that the sword is 6 feet long and the blade is 10 inches wide. I scoured the Internet for blueprints on this mammoth sword to make life a little easier but unfortunately did not find one. this is the closet thing I found.

So it was off to the drawing board. To save a little time since this commission has to be in it's new home by September 3rd. I drew it directly onto the MDF board itself. I went ahead and used 1/2 inch thick MDF board for the three main blade parts. I am also using a 1/1/4 inch hardwood dowel for the handle. So after drawing out the main blade I went ahead and cut it out and sanded down the top part of the sword near the hilt to give it the handle look that is hidden by the smaller side swords but can still be seen by looking down the top of the sword. I then cut out the 2 side blades as well and did a little sanding to get them in the final shape. Next I drew in the line that separates the main blade into it's 2 sections and penciled in the scallop pieces on the top blade. Next I brought out my router and went ahead and but the main groove down the blade to differentiate the two blades. Unfortunately that's when my router said you have put me through enough hell so I'm, not going to work anymore. It was at this point that I gave it a rest for the night. When my equipment craps the bed on me it's a good signal to quit while I am ahead. pictures of what I have done so far.

SO after tasking a trip down to home depot I have a new router and I went ahead and made the scallop marks on both sides of the sword. I also did a rough sanding of the edge of the blade. just to make it look more like a sword blade. This thing is huge it is going to take a lot sanding to get this thing smooth.

Next I went ahead and drilled the holes for the screws that go into the side blades. I went ahead and made the bottom of the holes a little wider so that the heads of the screws will be flush with the board so when I glue it to the main blade I will get a solid seal. Also again I did a rough sanding of the blade edge to get the look of a sword. Thing about these small blades is that you only put the edge on one side. That way when I glue it together it makes a seamless seam.

Now this sword is pretty frigging big. The blade length is 4 feet and I made the handle 2 feet. Now the number I found out there was that the buster sword which is close in size to this has a 17inch handle. The fusion sword is a little bit bigger so I went with the 24 inch handle but the hilt is going to take up good 5 inches and the nut on the end of the handle is a good 1 inch as well as the wider round part near the hilt. so the usable handle length is going to around 19 inches give or take an inch. I'm planning on the hilt part covering about 1 inch of the blade and the rest going down the handle.

More progress Pics

Hard to see but I made the handle piece for the small side sword I ended up trying a pass with the router and found that I would have to adjust the router table after each pass and it just wasn't looking right for me. So I went ahead and broke out the mitre box and hand sawed each groove in and then took one of my wood files and filed the groove in a little smoother.

Close up picture of the handle you can see it a little better.

Found out that what i thought was a quarter circle was not a quarter circle more like a 90 degree curve. So I went old school and broke out the graph paper. after a little measuring and trial and error and I have it worked out pretty well. This would be my stencil to mark the MDF board.

Laying out the cut pieces on the small side swords to trace over it onto the sword itself. I'm going off the prop picture and the 1/4 circle part is almost inlaid flush with the sword blade. So it needs to be routered out. yeah more sawdust.

Took a break from sawdust and made the nut for the end of the sword handle. 2 pieces of 1/2 inch MDF board and some glue more sanding to get it's shape right after the glue dries.

So this is the 1/4 circle piece and the other little decoration piece after I routered out the spaces and it fits pretty nice in the sword. It stands out of the blade like an 1/8 of an inch. So it should look pretty nice once it is painted.

yeah more progress. you can';t really tell from these photos but I spent the weekend finish sanding the blade. Now I'm sure I have a lot more touch up sanding to do once the first coat of primer on it but the edges are smooth and have a nice rounded edge to it. This sword is turning into one of my favorite projects. It's been a lot of fun (besides all the sanding that is)

So after finish sanding it's time to glue the small side blades on. So I glued on side on and let it cure overnight. and this is how it looks.

Looking like a sword now. So While that was drying I went ahead and did the hilt/pommel/ hand guard thing. Not sure which one it is technically called here so all of them will do. Basically i took a 1/4 MDF board and measured out where the holes needed to be drilled for the nuts and bolts poking through. So I did that and then took a 1/2 MDF board and marked off where the bolt heads were and drilled holes so that the 2 pieces of wood would be flush when I glued them together. Here's the gluing process.

And here's the gluing process for the other Small side sword.

Fun fun fun. So out of curiosity I decided to piece it together except for the handle and some various other parts and this pic is what I like to call preview of what is to come.

A closer shot of the small side sword and hilt/pommel/guard thingy.

And now from the other end.

This project is coming together very nicely and I can't wait to see it completed in all it's glory.

Quick couple pics of what the hilt is going to look like it's still in it's rough stage right now. i went a head and used a 3/14 inch steel pipe for the handle. I was using a 1 inch hardwood dowel but I was getting a little too much flex in the handle when holding the sword upright. with the steel unfortunately it added more weight but it also made it more rigid. nobody likes a droopy sword.

Another one with my hand open to see the size of the handle compared to my open palm.

One quick last one for the heck of it.

So I did a test fit of this monster with everything on it and clamps holding the various pieces together that I hadn't glued on yet and good god it was heavy. Way to heavy there was no way you could hold this thing one handed never mind having to lug it around for a convention. So back to the drawing board. The best thing about doing a project twice is that the second time it goes a lot smoother. I went ahead and made it out of 1/4 mdf board this time and the difference is incredible. I did go ahead and make the hilt as solid as possible since the sword is in 2 sections and the hilt is what holds it together. I was also able to use a hardwood dowel for the handle this time and that saved on the wight as well and since it is so much lighter there was no flexing issues at all. So I have a pic of it in completed form before painting. Here are some pics.

So it is looking good. everything is glued and final sanding and it's in the priming process right now. Almost done with this awesome project.

So I got 4 coats of primer on this bad boy today. I have switched from 32o grit sandpaper to 440 grit sandpaper between coats. You would not believe the difference that makes. you get a really nice paint job with it. It really is amazing it takes a little longer and you might have to do another coat of primer but it is so worth it.

I also have Painted the black hilt part on the sword. There are 3 coats of black on this bad boy. I also used 440 grit between coats as well nice smooth finish on it. I'm letting it dry for a couple hours before I tape up the black part and then paint the blade, handle, and nut. The last part will be to tape up the nut and put a nice coat or several of Burgundy on the handle. Then some more lacquer to seal it again and it will be done.

sorry the picture is blurry.

So I realized I never showed any pictures of the final sword. I've made 4 of these so far and the technique is still the same except that I invested in a drill press and now drill the holes for the bolts straight through the hand guard and the blade. After that I just cut a threaded bolt to size and secure it with a washer and a nut on each end, with a little glue so it stays put. Also I started wrapping the handle with red leather strips to help cushion it a little and to make it look a little more professionally made. Here's some Pictures of the last finished sword I made.