Get it into a basic square shape it doesn't have to be perfect, let it cool, and then reaheating the surface we can smooth things out and make it more precise. We will be placing 2 TB of softened plastic at the handle line we marked earlier. Deadpool's Tsuba from the film are square. Next we will be adding the Katana Guard or Tsuba. Once you have the sword fitting inside, cap off the other end with some softened plastic. You can sand the edges down to make it more square or leave the rounded edges either will work. The pipe looks brown here because I am using some scrap PVC that I had already painted previously. To do this, cut a piece of 1" PVC pipe down to size using the measurements in the template and heat and flatten it much like we just did for the blade but not as flat. Now we need to create the sheath or SAYA to do a test fit before moving forward. Using your dremel, a sander, file, or razor blade cut along that line, reheat the tip and press the tip together like we did in the Master Sword build. You can run under cool water when you have it and you should end up with a slightly curved blade like thisĭraw on the tip tapering from the top corner down to about 1 1/4" or 3.175CM down the opposite edge of the blade and then continue on the reverse side marking that same taper. Once it has cooled for a second and the handle will move but is not flimsy, quickly pull the pipe and give it a gentle curve as well as check for straightness. Make sure to keep the handle level as it begins to cool so that it does not become deformed. If you have clamps it is helpful to use them in the flattening process. When the PVC becomes pliable like a noodle it is ready, flatten it between two boards leaving the handle section hanging out. I am using a heat box to heat my PVC but a heat gun and foil works just as well like I did in the Master Sword build. We will be heating the PVC pipe to a little past the handle mark and flattening it like I showed in the Master Sword tutorial. Using the measurements provided in the template cut your 1/2" PVC pipe to length and mark out the handle. I will be walking through the process of making 1 sword so just keep in mind you will repeat these steps and make a second katana. īegin by downloading and printing off your template. I have made a template that prints to scale, makes this build super easy, and it's available on my web store.
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