SUPPLIES & TOOLS:
DIRECTIONS:
To print the patterns, click on the "Download Project PDF" button (above).
Costume:
Sword:
Craft Hack Tips and Tricks:
- Simplicity Pattern 1552 B
- Lacing trim
- Sash trim
- Sewing machine
- Scroll Saw, fine tooth blade
- Band saw, 1/4" blade
- Heat gun
- 3oz contact cement
- 8oz Mod Podge, Matte
- Painter's blue tape
- Brushes: 2" foam, #4 Flat, 1/2" flat, 1" flat
- Black E6000 Adhesive, 2oz (1)
- Black stretch vinyl fabric: 1 1/4"x 31"
- Muscle foam, 24"x 40: 1/2" (1), 1/4" (1)
- 2oz Folk Art, Metallic Paint: Sequin Black, Gunmetal Gray, Silver Sterling
- 2oz Deco Art, Extreme Sheen Metallic Paint: 24K Gold
- Paint palette
- Piece of scrap wood, 1"x 3"x 5" or 1"x 3"x 6"
- Pencil
- Clamp
DIRECTIONS:
To print the patterns, click on the "Download Project PDF" button (above).
Costume:
- Eliminate fur.
- Substitute black stretch fabric for back and arms of jacket.
- Step 15: Lacing, substitute pre-made lacing.
- Sash: Tape ends of trim to prevent unravelling. Pin trim centered on WS of sash fabric. Baste. Double fold long edges of fabric to cover edges of trim. Sew close to edges. Remove tape from ends of trim. Use E6000 to adhere metal trim to fabric. Let dry. Double fold ends of fabric to cover ends of trim. Sew close to edges. Sew ends of sash together to form a loop.
- Back all heavy textured fabric, on collar and facing of coat and upper sections of gauntlets, with faux leather. This will reduce rolling. Add additional horizontal stitching every 5" on the front coat facing panels. Use painter's tape to mark lines for stitching.
Sword:
- Cut out two each of the decorative guard layers from 1/4" foam. Use scroll saw.
- Cut out one of each of the two different blades with handles and guards from 1/2" foam. Cut blade sections with band saw. Use scroll saw to cut handles and guards. To cut between the guard and handles cut through the top of the handle close to the guard on one and cut through the bottom of the handle on the other. These handle seams will be glued back together after heated.
- Tilt band saw bed to a 45 degree angle. Clamp a piece of wood just below the blade to act as a jig for the bevel cuts on the sword blade. This board should not extend beyond the blade. The handle and guard of the sword will need to begin past the board. Cut beveled edges on the blades on edges noted on the pattern. The bevel cuts will be on opposite sides of the blades. See reference photos. Curve the foam to ease the sword blade down to the 45 degrees.
- Heat all the sides and edges of the parts to close the pores.
- Glue the cuts in the handles to secure the handles to the guards.
- Line up the two handles with the blades. Trace the location with a pencil. This will show the area to apply glue. Remove the top piece. Apply contact cement to the two sides that will be glued. Start at the handle/ guard end and press together. Line up the inside curves of the blade working down to the tip of the sword.
- Layer the first curve on the guard. Trace, glue and repeat for the other side.
- Layer the second curve on the guard. Trace, glue and repeat for the other side.
- Use foam brush to apply Mod Podge to all surfaces. Let dry completely.
- Use flat brushes to apply silver to longer part of blade on both sides.
- Apply gray to inside curve of blade and gold to all of guard and 1" from ends of handle. Apply a second coat.
- On the top surface of the first layer of detail on the guard paint two coats of black. Let dry.
- Brush small amounts of black into all the crevices and immediately wipe to blend out. With slight amount of paint on the 1" brush, stroke down the length of the blade. Wipe over this with another clean brush or a finger to soften any bold brush marks. This will give an aged look.
- Use E6000 to attach the fabric to the handle. Apply the adhesive to one short end of the 1 1/4"x 31" fabric. Attach the end to the inside of the handle closest to the blade. Spiral the fabric upward overlapping 1/2". Stretch the fabric and add glue to the back of the fabric once for each spiral. End the fabric on the inside of the handle toward the guard. Apply painter's tape to help hold the fabric in place until glue has dried.
Craft Hack Tips and Tricks:
- Sewing on heavy fabric: Replace needle for sharpest point. Use wide stitching.
- To cut 1/8" foam, use scissors or an X-Acto knife.
- For 1/4" or 1/2" foam, use a scroll saw for tight curves & a band saw for slight curves and straight cuts
- Use foam brush to apply Mod Podge. Most other brushes will leave a texture on the surface that will show up when painted with metallic or gloss paints.
- If puddles form in corners let the surrounding area dry for a few minutes. Use a #4 brush to even out the puddle.
- Store foam creations hanging to prevent denting.