How to make the Lone Wolf sword?

Sommerswerd, a powerful magical artifact, a golden sword whose abilities can only be fully harnessed by a true Kai warrior. This legendary blade belongs to Lone Wolf, the last of the Kai Lords. In this guide, we'll show you how to craft not just a replica of this sword, but any similar weapon.

What you'll need:

• EVA foam 0.5cm, EVA foam 1cm, and moosgumi

<li>[link type="Product" id="26190" label="Fiberglass"], or a wooden or plastic rod (0.5cm)</li>

<li>Contact cement (Chemopren)</li>

<li>Prime Seal</li>

<li>[link type="Product" id="55314" label="Foam Clay"]</li>

<li>Scissors, craft knife, ruler, pencil, paper, eraser, Dremel 4000 (or another powerful mini rotary tool), brushes</li></ul>

Step 1.

First, find detailed photos and dimensions of the sword online. Then, draw these dimensions onto paper at a 1:1 scale. Gathering all the data and sketching it correctly takes time and requires some adjustments, so an eraser is definitely essential.

Step 2.

Cut out the crossguard and the handle. I recommend doing an eye-test every time you change the size. Take your creation in your hand and stand in front of a mirror to get a better idea of how big the final product will look in your hand.

Step 3.

Prepare your fiberglass core (or any reinforcement of your choice) and cut it to the appropriate length. WARNING: The core splinters when worked with. If you are cutting by hand, for example with a hacksaw, wear gloves! Cut two long strips from EVA foam (the length of the blade). Apply contact cement to both sides, let it sit for 5–20 minutes, and then glue them together. Contact cement is the best glue for EVA foam, but you must follow the correct procedure.

Step 4.

While the glue is curing, you can start working on the crossguard. Cut it out of thicker EVA foam (1cm). Then, cut the inner decorative shapes out of moosgumi. The Sommerswerd in the book's illustration is very detailed, and I can't imagine how I would have achieved that level of detail with the materials I had at home. What you see in the picture on the left is handle version #1. You will encounter version #2 later. Unfortunately, some steps required redoing. But that's part of being a beginner :)

Step 5.

Model the pommels on the crossguard using Foam Clay and let them dry for 24 hours. Foam Clay is essentially a slightly sticky modeling clay that turns into an EVA foam-like material once dry. It's easy to work with and becomes adhesive when moistened.

Step 6.

Use a Dremel to sand the edges so they resemble a sword. They should be thin. Don't worry; if glued correctly, both sides of the foam will appear as a single piece, so the Dremel won't open or damage the seams.

Wear safety goggles and a mask or respirator when working with a Dremel. Small particles fly off when sanding foam. I definitely don't recommend inhaling them or getting them in your eyes!

The higher the speed you set on the Dremel, the easier it will be to sand and the smoother the surface will be. But 35,000 RPM really "kicks." Be careful, stay alert, and think everything through twice. Sand in the direction of the Dremel head's rotation, not against it! Even if it's tempting, you have less control when moving against the rotation.

Step 7.

Glue all parts of the sword together. Just like you sanded the blade, smooth out the crossguard as well. Attach the pommel modeled from Foam Clay.

Then, coat everything with Seal Prime. Unfortunately, I made a mistake here, which is why the surface isn't as smooth as it should be. I forgot about the work in progress in the workshop due to other activities. So, if you want your EVA foam to be beautifully and evenly smoothed, buy Seal Prime in a spray can. You don't have to mix anything, and it's easy to apply. I'm planning to buy it myself.

Once the Seal Prime is dry (24h), spray the entire sword with automotive filler or primer.

Step 8.

The rest is all about details. You can use leather or faux leather for the handle. Paint with acrylic paints and varnishes. Surprisingly, Army Painter miniature paints worked well for me too. They have a very nice gold.

And we're done! You can make practically any sword, dagger, or other cold weapon this way. In this case, the production took about 2–3 days, but most of the time was spent waiting for things to dry. The costs were around 600 CZK, but I will use much of the purchased material for other projects. With every project, you move forward and figure out how to do things better. Anyway, it was fun. And that's the main thing!

author Eva Lassler