Wow, the set is beautiful! I love how you added the wavy tempering along the edge, it adds that little touch to make the blades seem more convincing.
I've been trying to find out how to make a clear blade from plexiglass in case I ever get around to a cosplay I want to do. I've never made a sword before, though, so maybe I should try making wooden ones first.
I don't know exactly how thick the blade would need to be, but from what I've seen/read from other people's attempts at this particular sword, no one has bothered to shape the blade realistically. I've only seen one version with a somewhat convincing edge, but I think it was factory-made. Is the plexiglass for your ronin set 1/4", like the Adamants?
Any ideas/tips on how to work with the acrylic? I think I would probably have to use a thicker sheet of plexiglass, or shorten/widen the blade to make it more realistic and less likely to break. Maybe a combination of the two. Refs for the sword I want to make: [link][link][link]
Well making a plastic blade is pretty easy if you have the right tools. Practice on scraps.
Start with a piece of 1/4" Plexiglas. Use a template to draw 3 curves. The blade and the taper point. Cut it with a jigsaw with a fine toothed blade. Now cut and peel the paper on the plastic to reveal the part to be tapered. Shape it with a belt sander with the coarsest belt you can get. Taper it to close to a sharp edge. Do not work one part too long or you will melt the plastic.
Start hand sanding with a sanding block with 80 grit sandpaper and take out all the marks from the belt sander and sharpen the edge.
Remove the paper. Now with hand held sand paper sand out all the scratches using 120, 180, 220 grit.
Next wet sand it with 400 then 600 grit. Dry off the blade. If you want a tampered look cover the edge with masking tape cut to a wave pattern. Now with a polishing wheel and plastic rated abrasive polish the blade, again move the blade so as not to over heat one area.
Very cool idea doing the katana from acrylics. I also think about doing some similar one but I like to use a very dark blue and like to try make a "lightning" and maybe some magic glyphs into the inner middle. One thing I got as an idea was just cut from a plexy or acrylic plate. The other idea was to "die-cast" with liquid acrylics that hardening clear and can be colored individual. Would be could if you maybe can do a short tutorial on how to do with this kind of material and what to be need be checked carefully. I think you know *chioky he is realy very good in doing katanas in wood, and have some nice tutorial. How big is the material you used? And as someone mentioned before... how you got all the scratches and cutting marks so smooth and clear any tricks with polishing? I love the idea of crystal or glass like katana blades.. it gave so much mystical look to them as well as some scifi forcesword kind of look as well
you cut the plastic with a find tooth blade and shape it with a belt sander with an 80 belt. Then sand the plastic with 100, 220 sand paper, then wet sand with 400 finally 600 sand paper. Then cut masking tape with a wavy pattern and place it along the edge and polish it with a buffing wheel. When you remove the tape it will leave a wavy pattern along the edge like a real katana.
If you use a belt sander with a 120 belt to rough shape the blade with practice you can do a katana blade in less than 1 hour. All you need to do this is a jig saw, a belt sander, sandpaper and a buffing wheel.
Yeah, I kinda screwed up my last costume. But I really like these swords~ Ichigo, eh.... My hair's grown out since that photo, maybe..... I have less than a month to make the costume though, and he's overdone...
Here's what you do put on a T shirt like Ichigo wears carry a Kon Plushy and have some friends dress up, but not as Soul Reapers, one as Rukia. For cosplay have Rukia standing to one side talking to some other people. Someone play Kon's voice offstage and ask "Come on you fought Hollows and worse. You can do this." Follow along that theme with Ichigo saying things like, "This is worse" and in the end give a huge swallow loosen your collar and go over and ask Rukia " Would you like to go to the dance on Friday?" Keep the script along the line of NOTHING is scarier to a boy than asking a girl for a date.