From initially measuring dimensions against the reference art to cutting, sanding, priming, topcoating, and final assembly, the production cycle of Cosplay prop making for these six swords dragged on for quite a while. The most grueling part of Handmade props isn't the sanding, but finding a flat space to let the paint dry. Dormitory daily life doesn't offer much room between beds, and once all six swords were laid out, there was practically nowhere to step—my roommates had to squeeze sideways just to grab clothes.
The materials used were standard EVA foam and PVC pipes, with lots of effort put into the surface sealing. In particular, the metallic texture on the blade and guard required multiple spray coats; to get that reflective gleam under sunlight, I spent a long time picking out the right high-gloss lacquer. Bonding the gems and accessories also required extra care, since having pieces fall off this kind of large Kendo equipment prop during a shoot would be quite awkward. The hardest part of making this set was balancing length and center of gravity: if the sword is too long and light, it feels cheap, but if it's too heavy, it hinders posing while worn.
Here are some photos showing the results of my test fit. Because I took them in our messy dorm corridor with laundry hanging everywhere in the background—a sharp contrast to the intended flying-sword aura—I just covered my face and legs with stickers. The swords look truly gorgeous and golden in the sunlight, with a texture far superior to an overcast day, making all the frustration of crafting on the floor worthwhile. Wearing them instantly shifts your presence, though whenever I moved slightly, the swords clanked against the metal railing, echoing jarringly in the quiet dorm.
The entire rig together with these swords carries genuine weight. Doing a Costume fitting in shorts and slippers felt mismatched and didn't fully project the character's aura, but the primary goal was testing the mounting angles and stability—making sure the rig wouldn't wobble on my back or clip my legs during arm swings. Based on current tests, the angles feel natural once adjusted, and swinging them in hand isn't too strenuous; large props like this deliver a commanding presence when posed. This was mainly about testing the Handmade workflow myself and doing a hands-on Costume fitting to see what needs further tweaking, plus getting some fresh air in the sun.
Since I've already arranged with a client whose height and vibe match the character perfectly, these six swords and the costume were tailored to her measurements. My own try-on in the dorm was a bit cramped, whether in hair or silhouette. Once she wears the outfit with the wig, paired with professional makeup and a proper studio setting, the overall effect will look vastly better than in a hallway lined with hanging trousers. I'm really looking forward to her official photos!