After it dried I sanded it down so it would be level and made sure the rest of the sword was level. After sanding it down by hand I took some wood filler, I watered it down, and spread it all across the bottom of the sword. This kind of look is hard to get with plywood so I needed to make it smoother. Since the blade needed to look a bit different I used a metallic paint to make it look a bit more like it was sharpened. The top part (not the blade part) was easy since I used paint that gave it a hammered look all I needed to do there was fill holes and indents with wood filler after sanding it by hand. Now, the problem with plywood is that itâs not a natural wood, making it hard to make it nice and smooth so it looks good with paint. One I put those in with glue it just lit it sit over night. So I drill these indentations into the hand guard for the 5 half spheres on it. You should now have an unpainted buster sword with materia slots! I went out and happened to find these small half sphere pieces of wood at hobby lobby that had a flat looking round bottom that came out. Take some sand paper and start sanding on the inside of the holes, if you have some gaps I also suggest wood filler, but you probably wonât since you put glue on the big piece of wood. Now take the bit you want to use (I used some weird attachment to drill good circular holes) and drill away! Since you will also be drilling through that big piece of wood you will probably burn some wood with friction from the drill, this is normal. Now you need to mark where youâre putting your materia slots if you havenât already. Clean the surface of the sword, I used an air blower to get rid of all the little particles from sanding and such.
So that we have a nice buster sword looking thing there is still some things we need to do. You now should put the final medium pieces on the ends just like the others, you should have a nice buster sword shape that looks (and is!) almost done. Now take your wood filler and fill all the holes where you put nails, fill all the little parts that you need to and you can also put some on the buster sword to make the transition between the two pieces of plywood look a bit better (after painting of course). Turn it over and do the same thing to the other side. After you put it on nail it in place with the nail gun. While itâs still wet (make sure it stays on though) put some glue on the supports, back, and that big piece of wood so you can put the big pieces of the plywood on. Put it in between the two pieces of the wood so that they connect. Line up the two larger pieces of wood how they should be and then water down some white glue a bit and cover the fabric in it. Sand the edges and then take the fabric and white glue. Now we need to prep the large ply wood pieces to get them on the frame. You can move on to a different part but leave that part dry, you should now have a nice looking drying frame. Now put in the handle and cut it off a bit longer then you need it for the sword, at least that is what I suggest. Drill them through both Go ahead and glue them in place, clamp them and take the handle, cover the part of the handle that will be inside the sword with some gorilla glue, not too much but enough. Now use a bit that is a bit bigger then the large dowel you are using as a handle. Mark the center this is where you are going to drill the hole. Take some large pieces of wood (if youâre lucky like me they should just bee sitting near where you do all of your work and you wonât have to buy them). If you still want to do more work or you have come back after a day then youâre ready for the hand guard and handle.
#CLOUD BUSTER SWORD FULL#
That is quite enough work for one day, and you need to let this dry for AT LEAST 4 hours, but you should let it sit a full 24. Once you get it right then you should put them together. It would be a smart idea to test it out a scrap piece of the same wood. Take the gorilla glue and follow the instructions on the container and glue the supports in intervals on the back, take the nail gun (probably connected to an air compressor) make sure that the pressure is not too high since that will just go through the wood. Now take the back and the supports, you are about to put them together. Now that you have all that done then you can sand them down so they are nice.
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