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Kirito Great Sword Tutorial by Iloon-Creations Kirito Great Sword Tutorial by Iloon-Creations
A tutorial for how to make the Black Iron Great Sword from Sword Art Online (Alfheim arc).


Materials used:

- Grey board (2.5 mm thick)
- EVA foam
- Metal ruler
- Stanley knife
- Cutting mat
- Paper clay
- Universal hobby adhesive
- Contact adhesive
- Construction adhesive from Bison
- Wooden stick
- Sanding paper
- Painters tape
- Gesso
- Primer
- Silver metallic spray paint
- Black metallic spray paint
- Graphite powder
- Brown and black acrylic paint
- Paint brushes


- For the base of the sword I used 2.5mm thick grey board. I cutted out all the patterns. Because the material is very thick, you can't cut it in one movement. So I used a metal ruler and slichtly cutted the board by going over de drawn patterns a few times with my stanley knife.

- After I cutted out all the patterns, I glued on the edges with universal hobby adhesive. I glued on the wooden stick in the center of the board with construction adhesive and let it cure for a night.

- After the construction adhesive was cured I glued all the grey board pieces together and filled in the seams with paper clay. After the paperclay was fully harded out I sanded it down.

- Then I added the other details which I cutted out of EVA foam. I used contact adhesive to glue all the pieces together and glued it on the grey board. Again I filled in the seams with paperclay and sanded it down etc. For the details on the grid I used paperglay also and sanded it down.

- I sealed the foam with at least 2 layers of gesso, this is very important or else the foam will be too porous to be able to spray paint. After the gesso was fully cured I added a primer. After the primer was cured, I sanded everything with a 200 grid sandpaper to smooth everything out.

- Time to paint, I started with the silver part. So I sealed all the area's which are NOT silver with painters tape and sprayed a few thin layers of silver paint and let it cure for a few hours. Then I carefully removed the painters tape and sealed all the silver area's to be able to add the black paint. After the black paint was cured I added some graphite powder for a more metallic look and added some brown/black acrylic paint for a worn out look.


And the sword is done!



Tips an tricks:

When using grey board for making swords or other props, always use a sturdy core like wood or metal. For making swords like a katana I recommend wood because grey board will not be sturdy enough for a blade only.

As a filler you can use any material you want since there will be no pressure on the seams. I used paperclay because I already had this laying around.

If you want a more lightweight prop, you can also use foam board instead of grey board. Foam board is not as sturdy as grey board but it is possible. On foam board you can't use the contact adhesive and some types of primers, it can eat the foam board.



I hope this helps, if there are any questions be free to ask them.
Add a Comment:
 
:iconcuero69:
cuero69 Featured By Owner Oct 31, 2014
Hi, I'm currently trying to make Kirito's Elucidator for Comic-Con and wanted to know what did you use to cover the joints and what primer you used to cover the sword. Here in Puerto Rico they don't have grey boards going to try to do it on faom board, will the same primer function the same way?
Reply
:iconiloon-creations:
Iloon-Creations Featured By Owner Oct 31, 2014  Professional Artisan Crafter
I used paperclay to cover any gaps and joints. But any filler that cures in the air will do.

Don't use the same primer on foam board. It will destroy the foam, so don't use anything chemical on it.

Use PVA glue (woodglue), a few layers of it of any brand (as long it is not expandable) will do the job :)
Reply
:iconcuero69:
cuero69 Featured By Owner Edited Nov 1, 2014
Thanx so much!! Will do, if every thing goes smooth I'll post the final pics!!
Reply
:iconmrlgreenthunder97:
MrLGreenThunder97 Featured By Owner Aug 10, 2014
A great-a tutorial! XD
Reply
:iconarinuchi:
Arinuchi Featured By Owner Apr 18, 2014  Hobbyist Traditional Artist
I FINALLY FOUND SOMEONE ELSE WHO USES FOAM BOARD *gasps*
Reply
:iconcsabi911123:
csabi911123 Featured By Owner Mar 1, 2014
Hy, that's an awsome sword, I would like to make one myself but I have problems wirh the right size, couls you tell me about the parameteers of you sword? That would be a very big help, thanks.
Reply
:iconiloon-creations:
Iloon-Creations Featured By Owner Mar 22, 2014  Professional Artisan Crafter
Measurements of the sword can be found here:

www.facebook.com/iloon.creatio…
Reply
:icongreenvisual:
GreenVisual Featured By Owner Feb 18, 2014
Looks like swords inside of a cave
Reply
:iconoriginyl:
Originyl Featured By Owner Feb 12, 2014
Would you sell this? ^_^
Reply
:iconiloon-creations:
Iloon-Creations Featured By Owner Feb 13, 2014  Professional Artisan Crafter
No, sorry.
Reply
:iconlizzyfizzy:
lizzyfizzy Featured By Owner Feb 9, 2014  Hobbyist General Artist
Btw, what did you use on the handle of the sword? (end of the wood and connecting to the sword piece) Is it also foam?
Reply
:iconiloon-creations:
Iloon-Creations Featured By Owner Feb 10, 2014  Professional Artisan Crafter
It is paperclay ^^
Reply
:iconrhatios16:
Rhatios16 Featured By Owner Dec 26, 2013
Nice but since I have non of that stuff I have to use cardboard :D
Reply
:iconrhatios16:
Rhatios16 Featured By Owner Jan 2, 2014
Would you mind telling me the dimension of it though I think Im kind of off?
Reply
:iconlizzyfizzy:
lizzyfizzy Featured By Owner Dec 17, 2013  Hobbyist General Artist
Hi, I am currently trying to make this sword. I am a little confused on how to glue on the sides of the sword. How do you get them to lay at an angle? I glued them sticking vertically up. Also, near the end of the sword (where the stick is attached to the sword), what material did you use to make that detail? After painting the sword, the material resembles rubber. Did you use the eva foam or the paper clay to fill in the bottom of the sword? The tutorial is great btw! Sorry for the long questions. this is my first time making a cosplay prop.
Reply
:iconiloon-creations:
Iloon-Creations Featured By Owner Dec 17, 2013  Professional Artisan Crafter
I first glued both big pieces together without the sides. After that I glued small triangles on the sides and on top of that the sides :) I used EVA foam for all the details.
Reply
:iconkingspierre:
KingsPierre Featured By Owner Nov 12, 2013
The paper clay need to take how much time to let it become hard?If need to let it soft,need to add water?
Reply
:iconiloon-creations:
Iloon-Creations Featured By Owner Nov 13, 2013  Professional Artisan Crafter
Depends on the brand you use. I have it in a powder form and I add the amount of water until I am happy with the smoothness of it.
Reply
:iconkingspierre:
KingsPierre Featured By Owner Nov 25, 2013
I see~~~ok thx~~~
Reply
:iconim2lazy4aname:
Im2lazy4aname Featured By Owner Aug 16, 2013
if you do decide to commission how much will it be?
Reply
:icontriforcem7:
triforcem7 Featured By Owner Aug 14, 2013  Hobbyist General Artist
i cant find any grey board. so do you know of something similar? and also what type of foam is EVA foam exactly?
Reply
:iconiloon-creations:
Iloon-Creations Featured By Owner Aug 15, 2013  Professional Artisan Crafter
Something like poster board or foam board will do the job also. You just can't use contact glue on foam board, use universal hobby glue instead.

EVA foam is Ethylene-Vinyl-Acetate foam which you can get in lots of different types of density and thickness.
Reply
:icontriforcem7:
triforcem7 Featured By Owner Aug 15, 2013  Hobbyist General Artist

ok thanks so much! ^^

Reply
:icontriforcem7:
triforcem7 Featured By Owner Aug 7, 2013  Hobbyist General Artist
is it possible to make Kirito's euclidator and Asuna's sword following this tutorial?  
Reply
:iconiloon-creations:
Iloon-Creations Featured By Owner Aug 8, 2013  Professional Artisan Crafter
Yes, it sure is possible to use the same materials and techniques ^^
Reply
:icontriforcem7:
triforcem7 Featured By Owner Aug 9, 2013  Hobbyist General Artist
ok awesome! thanks!
Reply
:iconprimordial42:
Primordial42 Featured By Owner Jul 29, 2013
Is this Safe for LARPing? because me and my friend have our own SAO game and this would be great for him
Reply
:iconiloon-creations:
Iloon-Creations Featured By Owner Jul 29, 2013  Professional Artisan Crafter
As long as you don't use metal as a core, it will be save for larping ^^
Reply
:iconprimordial42:
Primordial42 Featured By Owner Jul 29, 2013
Ok thanks! This is gonna be epic!
Reply
:iconviewer934:
Viewer934 Featured By Owner Apr 30, 2013
do you do commissions?
Reply
:iconiloon-creations:
Iloon-Creations Featured By Owner Apr 30, 2013  Professional Artisan Crafter
Not at this moment, I am too busy with my fulltime study.
After this summer when I am I done with my study, I will ^^
Reply
:iconviewer934:
Viewer934 Featured By Owner Apr 30, 2013
Okay
Reply
:iconstealthhamster:
StealthHamster Featured By Owner Feb 20, 2013  Hobbyist Artisan Crafter
Would it be possible to use something like a thin cardboard without jepordising the structural stability and shape of the sword?
?
[link]
Reply
:iconiloon-creations:
Iloon-Creations Featured By Owner Feb 21, 2013  Professional Artisan Crafter
Depends on the type of cardboard, but it is possible. I only think that thin cardboard will make the prop less durable.
Reply
:iconstealthhamster:
StealthHamster Featured By Owner Feb 11, 2013  Hobbyist Artisan Crafter
Umm... Problem. Where did you get your grey boards?
Reply
:iconiloon-creations:
Iloon-Creations Featured By Owner Feb 12, 2013  Professional Artisan Crafter
In The Netherlands you can get it in arts and crafts stores. I am not sure about the other countries.
Reply
:iconstealthhamster:
StealthHamster Featured By Owner Feb 9, 2013  Hobbyist Artisan Crafter
Beautiful tutorial! Just one question, how long did you make the blade?
Reply
:iconiloon-creations:
Iloon-Creations Featured By Owner Feb 9, 2013  Professional Artisan Crafter
Thank you ^^
Full length of the sword is 145 cm. The hilt is around 40 cm so the blade is 105 cm.
Reply
:iconsweetdelphy:
Sweetdelphy Featured By Owner Feb 5, 2013  Hobbyist Artist
Amazing *-* I <3 SAO
Reply
:icontotalexistancefail:
totalexistancefail Featured By Owner Feb 3, 2013  Student Artisan Crafter
This is a good reference for making any foam sword prop! Thanks!
Reply
:iconpokelovermeso:
PokeLoverMeso Featured By Owner Feb 1, 2013  Professional General Artist
reminds me of making my swords for dagorhir
Reply
:iconsingingnight:
SingingNight Featured By Owner Feb 1, 2013  Hobbyist Artisan Crafter
thanks so much for the tutorial! ^^
Reply
:iconmikobura:
MikoBura Featured By Owner Feb 1, 2013  Student General Artist
Awesome work!!
Reply
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