September 30, 2003

Only 31 Days Away

I thought I would give you guys advice on the best way to make a nice looking, yet inexpensive and light weight weapon for your ninja, barbarian, or pirate costumes alike:
Gilding a cardboard sword:
· Coat one side of the sword with a thin even layer of rubber cement.
· Pull a piece of aluminum foil large enough to cover one side of the sword with a little extra for trim all the way around.
· Lay the foil out, shiniest side down, on a clean smooth surface.
· using a wad of toilet tissue, carefully rub the foil with just enough pressure to smooth out the wrinkles.
· Carefully apply a thin, even coat of rubber cement to the foil.
· Allow the rubber cement on both surfaces to dry until firm and tacky.
· Very carefully lay the glued surface of the foil over the glued edge of the sword.
· Again use very gentle pressure with a wad of toilet tissue to smooth any wrinkles and push air bubbles to the edge.
· Allow the rubber cement to dry thoroughly before trimming the excess foil.
· Repeat above steps on the other side of the sword.

Building a better sword:

Instead of using a single piece of thick corrugated cardboard as most people do, use two pieces of thick cardstock and a thin dowel. (No more than 1/4'' diameter'')
· Using the same pattern cut out two identical swords, hilts and all, from the cardstock.
· Apply thin, even coating of glue (NOT rubber cement) to one surface of each sword.
· Lay the dowel down on the glued surface of one sword along the centerline.
· Lay the other sword on top of the first half and the dowel making sure the two glued surfaces are touching.
· Use paperclips or clothespins all the way around the edges of the sword to hold both halves together.
· Allow sword to sit overnight before removing fasteners and applying gilt.

This type of sword is more durable and even has a realistic ''beveled'' look.