Magic Knight Rayearth: Fuu's Sword

I was commissioned to make a replica of the swords from the series "Magic Knight Rayearth". Fuu's was the first completed of the trio.



The poplar wood that I use for swords only comes in 4 ft lengths. To make up the extra length, I offset laminated the wood.



The wood glued together and cut to shape.



I shaped the edge on the sword with a belt sander and used putty to smooth the surface. Also shown are the other blades.



The handle was shaped on the lathe from Bass wood.



I used a long drill bit to core out the center to allow the 5/16" steel rod.



The collar of the handle has an irregular shape so I carved it out of the lathed shape.



The completed collar minus the recess on each side for a gem.



The pommel was formed by laminating 1/4" sheets of maple.



I attached it to a hand drill and smoothed out the base with files and sandpaper.



The final pommel test fitted to the handle.



The guard was made by glueing three sheets of 1/2" MDF together, leaving a hole in the center for the blade.



The guard rounded by router.



After the surface was primed, I cut the bird details from .09 styrene.



I used a heat gun to soften the plastic and press it around the guard.



I matched up the edges and puttied the seams.



While the putty dried, I added the second layer of detail with .06 styrene.



The completed guard attached to the blade.



The final painted and assembled hilt with cast resin gems.



The sword disassembles for transportation although it will have to be glued before using.



The whole sword. It measures 7 ft in total length!



Detail of the guard.



Detail of the pommel.