Guts Sword - Dragon Slayer from Berserk.

I wanted to try and design a full sized sword. Guts sword seemed easy enough to make and paint.

At 100% scaling the sword is ~1.5m long and 22cm wide, and weighs about ~3kg.

Wall mount available here.

Parts you'll need:

• A 25mm x 1830mm steel tube.
• Wraps

Tools

• Pipe cutter/ hacksaw/ grinder
• Glue
• Soldering iron
• Expanding foam
• Tape Measure

Instructions

• Print parts.
• Slide all the parts onto the tube.
• Using the tape measure, measure the excess tube length (it should be around 50cm).
• Cut the tube down to ~1.30m long using the pipe cutter/hacksaw/grinder. Sand the end to remove any sharp bits of metal.
• Using the pole as a guide glue Hilt A, Hilt B, and the blade cover together. Dont let the glue stick to the pole!
• Using the pole as a guide glue Blade A, Blade B, Blade C, Blade D, and Blade E together. Dont let the glue stick to the pole!
• Remove the pole. Let the glue cure for 24 hours. Cut off any excess.
• Use the soldering iron to seal up any seams between the parts (I used 300c for PETG).
• (Optional) Fill the blade gaps with expanding foam for added strength. You could also fill the tube with weights to try and balance the sword (its quite unwieldy).
• (Optional) Let the foam cure for 24 hours. Cut off any excess.
• Slide the hilt and blade parts onto the pole. Glue the Blade parts to the Hilt. Allow 24 hours to cure.
• Cut off any excess glue. Use a soldering iron to seal up any seams between the 2 parts.
  Done!

For painting, I sanded the whole sword down with a 60 grit, then 120 grit then 180 grit sheet. I then filled any gaps with milliput then primed with some grey primer. Once the primer was dry I painted the sword with 3 coats of silver spray paint and then 2 coats of black spray paint just down the center of the blade. After the paint was dry, I covered the whole sword in clear lacquer to protect the paint. I then attached the leather to the handle using the glue; the reel in the link is just long enough to wind around the whole handle.

08/06/2024 V1.1: Removed infills.

21/07/2024 V2: Decreased hole size from 28.5mm to 26mm. Added Blade cover.