Magic Knight Rayearth is a Japanese manga series. The story follows three eighth-grade girls who find themselves transported from modern-day Japan into a magical world, where they are tasked with rescuing a princess.
I was commissioned to make a replica of the swords from the series “Magic Knight Rayearth”. Hikaru’s was the last completed of the trio.
For the blade, I used 1/4″ Poplar with a channel cut to contain a 5/16″ steel rod.
Once the basic dimensions were cut, I shaped the blade edges on the belt sander.
The blade was shaped to leave a 1/8″ flat edge to make it “convention safe”.
Much putty, primer and sanding later, I have a smooth blade.
The handle was made from Bass Wood and turned on a lathe.
I clamped a hand drill and cored out the handle with a long drill bit.
I then cut the scallops at the base of the handle…
and used half-round styrene to make the trim.
I formed the detail at the top of the blade with thick styrene.
The flat gem detail at the blade tip was made with styrene and I filled the bevel gap filled with Bondo.
The hilt center layer was made by gluing 1/4″ poplar pieces. The second layer was made with 1/8″ MDF. The white plastic coating as sanded off.
The hilt center layer was made by gluing 1/4″ poplar pieces. The second layer was made with 1/8″ MDF. The white plastic coating was sanded off.
I used a Dremel to round off the organic details.
A quick test fit of blade, hilt and handle.
I started adding layers of 1/8″ MDF.
The center was built up with 1/4″ poplar sheets and trimmed with half-round styrene.
1/2″ MDF was used to make the base of the hilt center.
MDF was shaped to make the center plate.
The final painted guard.
The pommel was a cast resin 2″ sphere.
Cast resin gems were added to all parts of the guard.
The final sword.
The handle comes off for easier shipping. It will later be glued in place