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”. Umi’s was the second completed of the trio.
Since this blade is so thin, I wouldn’t be able to run a steel rod in the core. For maximum strength, I decided to use maple. I constructed a jig to tape the blade at a consistent angle. Once the basic dimensions were cut, I shaped the blade edges on the belt sander.
The handle was shaped on the lathe from Bass wood. I drilled out the center to accept a 5/16″ steel rod for connecting to the blade.
I used styrene sheets backed with Bondo to shape the upper blade area.
I made a quick cast of the guard area to sculpt the dragons out of clay.
I used epoxy putty to add scales to the dragon bodies.
A test fit of the cast resin dragon hilt
I made a maple plug to attach the dragon guard to the steel rod.
The painted guard with clear cast resin gem.
The final sword with cast resin gems.
Guard area details.
The sword disassembles for transportation although it will have to be glued before using.