Ichigo
Ichigo is the Main Character of Bleach. He was a human with high spiritual pressure, he then unlocked his soul reaper powers though event that I shall not disclose.
Thoughout the series he has multipe weapons. His weapon breakdown is identical to that of normal soul reapers. SEALED: The primary version of the weapon, this is a weapon without use or at rest. SHIKAI: The primary offensive mode of all soul reaper weapons. The weapon usually transforms in some ways to suit the user, some however do not. BANKAI: The maximum level of power, normally restricted to 13 captians of the 13 Court Guard Divisions or Gotei 13. However, mid-season he lost his powers. Eventually he reclaimed them resulting in a new SHIKAI and BANKAI. During a battle later on he broke his BANKAI, something that is irreparable under normal circumstances. He gets it reforged causing his SHIKAI to also change. His new BANKAI has not been revealed in the MANGA yet. Thus the order of Ichigo's weapons are as follows: SEALED: Zanbato 1st SHIKAI: Zanbato 1st BANKAI: Katana 2nd SHIKAI: Zanbato 2nd BANKAI: Odaichi FINAL SHIKAI: Daishō (A pair of matching swords, Ichigo weilds a small zanbato and a knuckle blade) |
Sealed
When I decided to make this sword, I first analysed the stresses involves. Its length was the greatest challenge.
Full length from pommel to tip, I had estimated at 190cm. The handle was the length of 3 and a half fists.
I estimate each fist to be 11cm. This makes my equation as so: (11x3)+(11/2)=33+5.5. I round the decimal point up to make a whole number.
33+6=39. I then round up to give me a more easily workable number. This makes the handle 40cm long, deducting 2cm for the tsuba leaves the blade at 148cm in length.
Relative to the photos the Blade width is less than 1/3 of the handle length but more than 1/4. As such I extrapulated the with to be 15cm.
With these measurements I made a 1:1 scale plan which then I cut to use as a template.
Full length from pommel to tip, I had estimated at 190cm. The handle was the length of 3 and a half fists.
I estimate each fist to be 11cm. This makes my equation as so: (11x3)+(11/2)=33+5.5. I round the decimal point up to make a whole number.
33+6=39. I then round up to give me a more easily workable number. This makes the handle 40cm long, deducting 2cm for the tsuba leaves the blade at 148cm in length.
Relative to the photos the Blade width is less than 1/3 of the handle length but more than 1/4. As such I extrapulated the with to be 15cm.
With these measurements I made a 1:1 scale plan which then I cut to use as a template.
By using the plan as a template I was unable to save it for future use. However I can use the actual prop to read the measurements and then make the plan in AutoCAD. In the mean time I have use of the Prop. I even tried to make a 'Holster'/scabbard for it while allowing enough freedom to be able to draw it.
The sword is made from 12mm MDF, to give substantial resistance to flex unlike the 1st SHIKAI. I painted it with Aerosol Paint Cans, so that it would dry fast and not leave brush marks. I used a combination of Dark Grey, SIlver, Gold, and white. I wraped the handle in white fabric and added a ribbon of Blue and the end of the pommel. I did not bevel the Blade as it would have exposed the softer MDF core to the elements. And as MDF particals can be cancerous, minimised that risk by not beveling. Due to the fact that I was making the weapon to take to Comic con, I only painted the apperance of a bevel, making it ideal in crowded areas so as to not hurt anyone. |
1st shikai
Ichigo's weapon has a name when it changes form, whether it be SHIKAI or BANKAI. Its SHIKAI name is Zangetsu.
When I began searching for reference imagery, I stumbled across the ManAtArms screen shot of their Zangetsu. When I watched it, I absorbed the information the blacksmith was saying including some measurements of the sword. That coupled with my own design allowed me to make it. In a burst of excitment and energy, following the blacksmith I designed the sword onto a large scrap of 9mm MDF, and proceded to cut it out on the Band Saw. I decided to make mine different from the ManAtArms design by focusing more on the anime design, featuring an exotic curve and tooth instead of curve to the handle which provides better practicality. The dictated measurements are: FULL LENGTH, 72" BLADE LENGTH, 48" BLADE WIDTH, 9" HANDLE LENGTH, 20" HANDLE WIDTH, 2" GRIND WIDTH, 3" |
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After rough cutting on the band saw I took used Sand paper to refine the shape.
I did not bevel the Blade as it would have exposed the softer MDF core to the elements. And as MDF particals can be cancerous, minimised that risk by not beveling. Due to the fact that I was making the weapon to take to Comic con, I only painted the apperance of a bevel, making it ideal in crowded areas so as to not hurt anyone.
Due to my haste in the making, I did not notice a structural weakness. The blade is weakest when held flat as the handle does not have as much support and the weight is not evently distributed.
Perhaps I can solve this problem, in the same manner that the blacksmith of ManAtArms did, by layering a section of Pine on the handle that extends past the 1st spike. The piece would be aproximately 22" in length with a chisel grind on the end, thus sloping into the blade.
I did not bevel the Blade as it would have exposed the softer MDF core to the elements. And as MDF particals can be cancerous, minimised that risk by not beveling. Due to the fact that I was making the weapon to take to Comic con, I only painted the apperance of a bevel, making it ideal in crowded areas so as to not hurt anyone.
Due to my haste in the making, I did not notice a structural weakness. The blade is weakest when held flat as the handle does not have as much support and the weight is not evently distributed.
Perhaps I can solve this problem, in the same manner that the blacksmith of ManAtArms did, by layering a section of Pine on the handle that extends past the 1st spike. The piece would be aproximately 22" in length with a chisel grind on the end, thus sloping into the blade.
1st Bankai
Using referrence imagery I noted that Ichigo's 1st BANKAI was a simple katana. At that time I had yet to create my Katana Blanks (which will be explained in another page).
His 1st BANKAI name is Tensa Zangetsu.
His 1st BANKAI name is Tensa Zangetsu.
It is a rather simple Black katana, it has a Manji styled Tsuba, a Black on Red handle wrap and a chain hung from the pommel.
At the time of construction I was going to Comic Con and so I simply prepaired tool, equipment and a selection of pieces. I assembled and finished the product in England. I made the Tsuba in two halves in order for them to interlock into one another, while trapping the blade in the Centre. In my tool box I included: wood glue, aluminium ducting tape, cotton line (commonly used by bricklayers), Black areosol paint, a chain with a screw eyelet on one side, a chisel, a small tennon saw, some sand paper and a scalple/X-acto knife. |
Using the tool I had brought with me and a section of Pine that I bought at a B&Q at Tottenham Hale.
having already experimented on afixing the tsuba onto a section of pine of a similar size, I repeated the procedure.
I began by cutting two notched out of the pine to be able to accomodate the Plywood Tsubas.
Once attached I proceeded to Spray the whole sword with 2 coats of Black paint, while sanding inbetween layers.
I left the Aluminium tape till the end in order to not affect the metalic finish during the other steps.
I wraped the handle in the cotton cord, glueing it down with wood glue, after the glue had set I painted overit with the aerosol. This stiffened a few of the loose fibers but a pair of scissors was enough to tidy that up.
I carefully cut the Aluminuim tape to the length of the blade and removed the protective backing taking care to ensure that the tape would not coil onto itself. I applied it to the blade and trimmed the excess off with a scalple. This left the edge of the weapon with what appeared to be a 'live' edge.
I finished off by attaching the chain with the eyelet screw into the pommel of the Handle and it was done.
having already experimented on afixing the tsuba onto a section of pine of a similar size, I repeated the procedure.
I began by cutting two notched out of the pine to be able to accomodate the Plywood Tsubas.
Once attached I proceeded to Spray the whole sword with 2 coats of Black paint, while sanding inbetween layers.
I left the Aluminium tape till the end in order to not affect the metalic finish during the other steps.
I wraped the handle in the cotton cord, glueing it down with wood glue, after the glue had set I painted overit with the aerosol. This stiffened a few of the loose fibers but a pair of scissors was enough to tidy that up.
I carefully cut the Aluminuim tape to the length of the blade and removed the protective backing taking care to ensure that the tape would not coil onto itself. I applied it to the blade and trimmed the excess off with a scalple. This left the edge of the weapon with what appeared to be a 'live' edge.
I finished off by attaching the chain with the eyelet screw into the pommel of the Handle and it was done.
When I took it to the event I was pleased to see that the sword I had made, which in my opinion was rushed, was well recieved. I was even asked where I had bought it from, my response caused a slew of raised eye brows when I stated i had made it in two hours, the previous Tuesday. This was infact my first ever Comic con, as well a first ever attempt to make a weapon for costuming events.
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2nd shikai
Ichigo's 2nd SHIKAI, is simply a giant kitchen knife or tactical knife. As with the 1st SHIKAI I concluded that its size would be to difficult to make out of Pine as that would add short grain problems as well as too nuch weight for anyone to carry.
As with my sealed construction I made a full sized plan, using the SEALED along with the 1st SHIKAI, to get the proportions accurate. Then I cut out the plan to use as a template. Being that it was such a large Zanbato, I did not trust myself to accurately transfer the measurements and redraw the plan onto the material and so I sacrificed the plan.
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The template was layed on the floor of my house which I had demarketed with masking tape to the size of a full sheet of 12mm MDF. The SEALED, 2nd SHIKAI and FINAL SHIKAI were all made at the same time out of the sheet. An adjustment I made to this sword, in order to make it more secure, was to increase the width of the handle from 4cm to 5cm. My hand does not have any problem wrapping around it and it fufills it perpose. The widend handle along with using thicker MDF helped maintain structural integrety. It would still flex under load of its own weight but was far easier to control vs the 1st SHIKAI which would wobble excessivly.
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Similar fashion to the SEALED and 1st SHIKAI I cut it out with a band saw and refined the edges with sand paper and painted it with Acrylic Aerosol Paints. On this piece I made a mistake when masking the 'bevel', causing me to repaint the sword. In total the sword had a minimun of 6 layers of paint. As with the other MDF sword I have not beveled it. The sword and the paint stood up admirably on the day of the Con. That day we had an unexpected rain and hail storm which cleared up in twenty or thirty minuites. The sword which I used to great effect as a shield survived rather unscathed from this event.
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2nd bankai
Ichigo's 2nd BANKAI is an Odaichi giant katana, with upturned tips and a full cut fuller. Its tsuba is distinctive ftom the 1st BANKAI's Manji tsuba in its more angular and agressive design. I do not have a pattern/plan for it as I built it on the fly and sketched it out onto the material i was buying.
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I started by purchasing a section of 10mm x 100mm x 2500mm. I cut the section in half, making two pieces of 1250mm in lenght.
I proceeded in laminating the layers to produce the desired width, as 10mm was too thin to move or weild without excessive movement. The basic shape was made using a Band Saw and evened up with a drum sander. Unlike the MDF swords, due to Pine having a uniform density, unlike MDF with a soft core and finish layers, I was able to use a 45° router bit to give the blade an edge along the front edge. Using a fence and a staight cut bit, I plunge cut the fuller out of the sword. I made the handle of the sword out of 2 pieces of MDF which I made a groove through, in order to accept the Tang. The sword and Tsuba was painted in gloss black aerosol paint and the handle was painted red and I used black fabric to try to replicate the diamond pattern along the handle.
I proceeded in laminating the layers to produce the desired width, as 10mm was too thin to move or weild without excessive movement. The basic shape was made using a Band Saw and evened up with a drum sander. Unlike the MDF swords, due to Pine having a uniform density, unlike MDF with a soft core and finish layers, I was able to use a 45° router bit to give the blade an edge along the front edge. Using a fence and a staight cut bit, I plunge cut the fuller out of the sword. I made the handle of the sword out of 2 pieces of MDF which I made a groove through, in order to accept the Tang. The sword and Tsuba was painted in gloss black aerosol paint and the handle was painted red and I used black fabric to try to replicate the diamond pattern along the handle.
final shikai
Ichigo's FINAL SHIKAI is a Daishō Pair of sword. Ichigo had a small Zanbato as his Primary weapon and a small Knuckle blade and a Secondary.
As with the other oversized builds I made these from MDF, even though I could have used Pine due to them be remarkably smaller. Made from the same sheet as the SEALED and the 2nd SHIKAI means that these will be 12mm in thickness and being MDF they will not be beveled. As with the SEALED and the 2nd SHIKAI, I made the plans then turned them into templates to mark onto the MDF. |
Cutting out the recesses and holes required the use of Drills, Jigsaws and the router, aside the use of a Band saw and stationary sander.
When it got to painting I changed the paint scheme as no-one knew what it was supposed to look like. I shot the whole body of both pieces with Matt black then masked off the body away from the 'edge' and shot that with Gloss black, making it apear that the edge was ground, follewed by a 1cm border of silver paint on the gloss black, 'refining' the edge.
When it got to painting I changed the paint scheme as no-one knew what it was supposed to look like. I shot the whole body of both pieces with Matt black then masked off the body away from the 'edge' and shot that with Gloss black, making it apear that the edge was ground, follewed by a 1cm border of silver paint on the gloss black, 'refining' the edge.