I was commissioned to make Taki‘s swords Rekki Maru and Mekki Maru from the Soul Calibur video game.

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I started by cutting grips from 1/4″ MDF, scribing lines across the surface of each.

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The blades were made from 1/4″ poplar. I beveled the edge of each blade on the table saw.

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After the edge is cut, I shaped the points and finished the bevel on the belt sander.

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The final sanded blades painted.

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I created many of the parts for these swords with a 3D printer from a Dutch company called Shapeways. Since they charge by the amount of plastic used, I made each part hollow and in half. After some cleanup, I would make a mold and make resin copies for the final swords.

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To wrap the grips, I ordered tsuka-ito (the grip wrapping) from China. I had to order 150 feet although I only needed 11 feet for each grip.

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I cast two halves of the Mekki pommel and glued them together.

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The completed pommel for Rekki Maru.

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The cast resin grip collars and decorative blade bases glued to each sword.

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Once the blades were completed I could construct the scabbards for each. I made MDF boxes lined with soft cloth to protect the finish on the blades.

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I started to round the scabbards by making angled cuts on the table saw.

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After the major cuts were done, I finished rounding them on the belt sander.

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I forgot about the lion-shaped grommet for Rekki’s scabbard so I got a second package from Shapeways. The printed pieces arrive with a sandpaper-like texture that has to be smoothed.

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The hollow back of the lion grommet. I will fill this with clay and cast the piece as solid resin.

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I glued the cast resin halves of the scabbard collars and bases together.

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A quick test fit shows a nice snug fit!

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I rounded the base of both scabbards to fit the new resin tips.

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I cut a plate from 1/4″ poplar for the back of Mekki’s scabbard.

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I blended the space between the scabbard and the back plate with Bondo.

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I cut trim from thick styrene and heat formed it to shape.

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I then applied epoxy putty to form the scroll work on the trim.

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I used a link of plastic chain and a tube cut from a mechanical pencil for Mekki’s inset area.

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I vacuum formed a styrene cover plate for Mekki’s inset area.

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I applied a border cut from thin styrene around the opening of the cover plate.

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I cut thick styrene strips for the front and back of Mekki’s scabbard.

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I painted Rekki’s scabbard with a base coat of white over grey and then applied a texture using plastic wrap dipped in white acrylic paint.

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I cut side plates from bass wood to border the inset area.

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I started shaping the side plates and carved the center to make trim.

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A coat of primer to see how everything is working together.

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I heat formed some final styrene details on the cover plate

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I found some ribbon of the proper width and color to wrap around the inset.

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I gave Mekki’s scabbard its paint job and applied the 3D printed symbol at the base of the cover plate.

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To wear the swords, I used mirror rosettes and swivel rings attached to the back of the scabbards.

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Hanging hardware attached to Mekki’s scabbard.

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I wasn’t able to find gold ribbon in the proper width, texture and color make Rekki’s scabbard ribbon, so I found the closest match in size and texture and painted it with gold acrylic.

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The ribbon applied to Rekki’s scabbard.

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The painted lion grommet attached to Rekki’s scabbard.

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I found a tutorial online for tsuka-maki (the Japanese method of wrapping sword handles) with tsuka-ito (the ribbon used to wrap it).

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The final wrapped grips.

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Mekki’s scabbard features a magic scroll wrapped around the center. I printed both sides of the scroll and glued them to both sides of thin aluminum. The metal could then be bent to shape and tightly wrapped around the scabbard.

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The completed Mekki Maru!

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The completed Rekki Maru!

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RESOURCES TO MAKE YOUR OWN:

Plans

Blindsquirrel’s Shapeways Shop

If you don’t want to go through the cleanup and mold making of the 3D parts, contact me for resin copies.

Tsuka-maki tutorial

I also have a limited quantity of tsuka-ito for sale. Contact me for details.

Mekki-maru’s magic scroll

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