A kunai is a Japanese tool originally meant for farming in the Tensho Era of Japan (1573–1592). In the hands of a martial arts expert, the kunai could be used as a multi-functional weapon, commonly associated with the ninja.
I was commissioned to make a replica of this traditional Japanese weapon….only HUGE! The client wanted it 4 feet long for cosplay.
I constructed a 3D model of it in Strata and then imported it into Pepakura for conversion into a building pattern.
I printed out the pattern, cut the knife sides out of .09 styrene and then glued in ribs to support the form. I cut a hole through the ribs for a 1″ dowel that will run through the entire prop.
The spaces between the ribs were filled with an expanding foam. The tip has been sanded flat in preparation for skinning.
The final panel was glued in place.
I used a 2″ PVC pipe for the handle. I inserted MDF spacers to support the wooden dowel.
The handle slides onto the dowel and is glued into place.
The end ring was made from layers of MDF to form a hollow box.
The box glued together except for the top so I can work out the handle join.
I rounded the box edges with a 1/2″ router bit.
The box glued together with the handle opening cut out.
The four sides of the back of the blade were glued into place and filled with foam.
The final blade painted with primer.
The interior was filled with expanding foam and the MDF was sealed with shellac.
The ring glued on.
The painted knife.
I dyed 1/4″ cotton rope red (per client’s request) and drilled a hole in the handle for the start of the wrap.