Making
a Mastercrafted Modular Sword is an art and not to be undertaken
lightly. First off, begin by knowing that your first sword will
probably be a throw away, and have plenty of supplies on hand
to get it just right. A list of the supplies you will need from
the Mastercraft Page follows, along with pictures of step by
step construction.
A video of making
Blades and Hilts is now available!
Mastercraft Modular Swords-
What You Will Need:
1) 2 1/2' long piece of Fiberglass Rod (Electric Fence Pole)
2) 8" piece of 1/2" schedule 40 PVC pipe.
3) 3 feet of 1"X1" dense block foam (not hard
but tough)
4) 9" of the above in a 2"X1" format.
5) 3 feet of 2"x1" high compression block foam
(softer stuff)
6) Block Foam, about 3"X3"X1" should do.
7) 6" square of Celephane.
8) 1' of 3/4" thin wall PVC pipe, the 200 class.
9) 1 Roll of 300 mil duct tape
10) 1 sheet rock screw, 1/2" long
11) Leather
12) Foam Glue |
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- Begin by cutting the piece of fiberglass electric fence
pole to about two inches short of the length you want your
finished sword to be (it will end up a bit longer because
of the compression tip and the length of the hilt and pommel.
Take a small amount of scrap foam and wrap it tightly around
the end you intend to use as the handle. Tape it in place
completely covering the foam with tape (the goal here is to
bulk up the rod so that it fits snuggly into the PVC pipe.
Cut a 6 inch section of the 1/2 inch Schedule 40 PVC pipe.
This will be the tang of the sword and will be inserted into
the hilt later on.
- Next, insert the the bulked up pole into the 1/2 in PVC
pipe. You may have to twist or screw it in or may have to
remove some foam if you have put on too much. Be sure it is
snug though, you do not want it to slide around inside- this
is critical
.
- Once you have it all the way in, tape rod to the PVC where
the rod extends out to the tip of the sword (where the cross
guard will be later). Make sure to tape it tight but do not
use a lot of tape. This piece of 1/2 inch PVC needs to fit
into the 200 class thin wall PVC pipe, and if you put too
many layers of tape on it will not fit in.
- Next, turn to the tip of the rod (what will be the point
of the sword). Take your dense block foam (like Evatech Foam)
and cut out a 1 inch by 1 inch by 2 inch rectangular prism.
- Cut a slit in the bottom and use the end of the rod to carve
out a hole in one end that goes half way through.
- Next, spray some of your foam glue into the hole (just a
little). Cover the end of the rod in duct tape (so it won't
tear through the foam) and then insert it into the hole.
- Cover the foam with a layer of duct tape being sure to secure
the foam block to the fiberglass rod.
- Next, turn your attention to the softer blade foam. Cut
out the desired size and shape of the blade. The blade needs
to be more then 2 inches wide but not more than 5.
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