Magic Knight Rayearth: Umi's Sword 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.



I turned the wood to cut the front profile.



Once the basic dimensions were cut, I shaped the blade edges on the belt sander (not shown).



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 filled with Bondo to shape the upper blade area.



I made a quick cast of the guard area to sculpt the dragons.



I used epoxy putty to add scales to the dragon bodies.



I sculpted the guard using clay trying to keep it symmetrical so the two sides will match up.



The completed sculpt. I made a mold of the body and head for casting in resin separately.



A test fit of a casting of the dragon. The gem master is made from a wooden sphere.



I added the plates to the base of the handle using styrene and Bondo.



I made a maple plug to attach the dragon guard to the steel rod.



The assembled guard test fitting with the gem master.



The assembled and primered dragon guard



The guard painted.



The final sword with cast resin gems.



Guard area details.



Detail of the hilt.



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

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