Christmas 2016 Project: Runescape Scimitars; update
Shortly after announcing my plans to make 6 Runescape scimitars for some friends of mine for Christmas, I practically dropped off the map, social media wise, when it came to updates on this project. I am honestly sorry that this is the case, but I became suddenly and unexpectedly busy with work. However, I have managed to make some progress on this build. I expect to make considerable progress in the two weeks before the 25th, as I have a promised time off. In the meantime, however, enjoy a quick pic of what I have accomplished. I donât know if Iâll do a big long write-up like I have in the past, but I will still share progress pics, like the one below. It is my desire to make a seventh foam sword for my myself (either the Sword of Edicts or the recently released Elite Wilderness Task set sword) and film the entire process, showing how I made it. (Among fellow prop maker circles my process is quite similar, but it would seem that the Runescape cosplay community is fairly unfamiliar with EVA foam as a construction material, and Iâd love to show them its low-entry-level but high-end-appearance result.)
From left to right: Steel, mithril, adamant, bronze dragon, and iron scimitars. Each one is made from 5 laminated layers of 1/4ⳠEVA foam from tntcosplaysupply.com with a length grey PVC pipe laminated in-between those layers as the core. Each scimitar was scaled, both in handle and blade length, to the person for whom it is intended. In other words the proportions were determined by the original blueprint I made in Inkscape, but the dimensions were dictated for the individual. The longest is the adamant, with a roughly 24Ⳡblade and 7Ⳡhandle and the shortest is the bronze at roughly 16Ⳡblade and 4Ⳡhandle. The profile to each scimitar has been blocked out, and the edge bevel sanded to shape. Some hand-sanding to perfect those edge bevels and some minor detailing on one or two of the scimitars is all that remains before I apply paint.
Given as I intend these foam âswordsâ to be full-contact toys (basically just like a NERF sword) a rigid inner core is mandatory. For this build I made both the handle AND the rigid inner core from the same piece of PVC. I used 3/4âł grey PVC for all but the iron and bronze âscimmiesâ. For these other two I used 1/2âł grey PVC, as it better suited the small hands for whom the handle/scimitar was intended.
A quick note on the PVC core: Ordinarily when PVC is used as a core to a prop foam weapon it is left round throughout. To compensate the prop must be made thicker. Generally this isnât an issue as game designers and developers prefer to make weapon and armor models that are much thicker than real life anyways (for technical reasons in the computer world). However, I didnât want these scimitars to be 3+â thick. Instead, I chose to make them 2âł thick, and heated and squished the PVC flat. Rather than stress the crease line of the squished PVC, I chose to first rip each pipe down its length, stopping at the handle. These now two separate layers of PVC had to be secured together to make it rigid again. If I am able to video record making my own sword, Iâll provide a much more in-depth visual guide to explain this process.
NOTE ON USING GLUES: Using grey PVC versus the more commonly known white PVC offers no difference in rigidity or any otherwise side effect. I simply had more grey PVC than white lying around, so I used it instead. It is worth pointing out, however, that grey PVC is often, but not always, made from ABS plastic. ALWAYS READ THE SIDE OF THE PIPE TO KNOW WHICH TYPE OF PLASTIC IT IS MADE FROM! With this information, purchase your adhesive accordingly. So if you use grey ABS piping, get ABS cement. If you use grey PVC, use grey PVC cement. And if you use white PVC, generic PVC cement is what you want. This detail matters, otherwise the glue, which forms a bond by slightly melting the two plastics together, will not form. Alternatively, a strong 2-part epoxy can be used instead. I feel this might be a better adhesive to use anyways instead of PVC cement, which isnât intended to handle the lateral stress of the two PVC surfaces rubbing and pulling against each other in the laminated way I employed. 2-part epoxy âfeltâ better for this application, but there is no science to back this claim up. As an alternative to either of these two glues, contact cement works just as good, albeit it tends to be slightly more flexible (just as it states on its own label). Again, if I make a video on making my scimitar, I will explain all this better with visual aid.
A happy accident I discovered along the way was that by laminating so many layers of foam together, I essentially form a ply-foam (just like plywood). It is my understanding and opinion that under certain circumstances plywood can be extremely more resilient than standard lumber. Fortunately, these circumstances fall under my needs for these foam scimitars. I canât say for certain if this is greater than-equal to, or less than a foam prop with a rounded PVC core (remember I squished mine to make these scimitars thinner), but it would seem that it is more rigid. Either way, I am pleased with the result.












