How to Make a Cosplay Sword (You Know You Want To ;))

Ever gone to a fan convention? You know, one of those mega nerd fests where people actually PAY to socialize with other nerds because that’s probably the only way they’re capable of making friends (myself included). There are huge, wall sized banners up of selections from all your favorite mediums — comic books, movies, games, anime, you name it. Artists and vendors are selling all kinds of themed merchandise that you know(don’t lie to me) that you’re about to blow all your money on. From concerts to meetups to interviews, the entire weekend is fully stocked with events that’ll keep you rolling on a constant high. But you know what kills that high real fast? Being that one lame guy not decked out in an awesome cosplay.

Here’s how to not be that lame guy.

First, you’re gonna need paper, some tape, and basic drawing skills. Tape several pieces of paper together to create a canvas as large as you want the full sized sword to be (or get a gigantic piece of paper, whatever works for you). Sketch out the basic lines of the sword: the outline, where the bevel should fall, and any other design breaks. Cut out the outermost line, we’ll work our way in.

Now get some EVA foam. This kind of foam is durable, flexible, and withstands heat. Trace the paper pattern you just made onto the foam and cut it out using an x-acto knife. Repeat this process for however many layers thick you want the sword to be.

**NOTE: use an x-acto knife and NOT a box cutter, it’ll tear up your hand otherwise.

Carve out space in the middle layer of your sword to place support. I prefer wooden dowels as they’re sturdy yet cost efficient. Use hot glue to secure.

Add LEDs as desired.

Put all the layers together using hot glue or rubber cement.

Cut out the other details on your paper pattern from the outside in and trace each level onto your sword.

Use a sanding tool of some sort to carve out the bevel of the blade and any other details. I highly, highly recommend investing in a dremel.

Special tip: if you carve lines into the foam, then heat gun the carved areas, the lines become more distinct, allowing you to create linework and other weathering effects.

Thoroughly sand down the sides where the layers are exposed. If desired, paper mache them, and then sand again.

Use a heat gun to seal the cells on the foam.

Prime the entire sword in plastidip or gesso. Or both.

Spray paint like a vandalizing maniac. The entire campus is your canvas.

Optional step: weathering! Use a dry paint brush and scrub the sword with a dark paint to create a worn effect.

Use a sealant to protect the paint and keep it from rubbing off on other surfaces.

And you’re done!

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