This is a crazy project and it is quite a bit of work. But if you are a fan of the Soul Calibur series of games and want something really spectacular then this is the project for you!!! And, the eyeball in the project actually moves! I love it.

I also have a video of this project at the bottom of the page.

I also have lots more projects on my youtube channel here.

Materials you will need for this project:

• Big piece of cardboard (At least six feet long) You can tape together pieces to make a long piece.
• Masking Tape
• Duct tape
• A serrated knife to cut the foam
• Newspaper for paper mache
• Paper mache mix (flour, water and salt)
• Wooden dowel or broomstick for handle
• Appx 6 cans of Great stuff (Great Stuff 157911 Gaps and Cracks, 20-Ounce ) You can buy at Home Depot or Lowes.
• Plaster Cloth for the handle (optional) Woodland Scenic Plaster Cloth, 10sf [Toy]
• Balloon (to make the eyeball)
• Wire to operate the eyeball
• Various paints like Silver, black and red
• Mod Podge

Let's Get Started!

Get a big piece of paper or tape together a bunch of sheets so you have one large sheet that is a bit over six feet in length.

Use pictures as a reference and draw out the shape of Soul Edge like this. It doesn't have to be exact because we will work it a lot. Just get the basic shape down and draw in an eyeball roughly where it should go. Then cut it out like you see here. This template is a little bit over six feet in length.

Now do a similar thing with corrugated cardboard or foamboard. Get a big piece or tape together smaller pieces to make one over six feet. Put your paper template on it and trace it. Then cut that cardboard piece out.

Cover one side of it with a layer of Great Stuff and let it dry. Once it is dry add a second layer right on top of that. This second layer isn't mandatory but it will make the sword thicker. Your option.

You can buy Great Stuff in Home Depot or Lowes. It is also available on Amazon.com.

Great Stuff 157911 Gaps and Cracks, 20-Ounce

There you go. The first layer is done and drying.

Once this first side is dry, whether one or two layers, turn it over and do the same thing on the other side. Once that dries you can do some carving to get it into shape.

A serrated kitchen knife like this works very well for carving the sword.

Once you have it carved the way you want it you can switch to sand paper or emory paper to further shape it and smooth it.

Now let's prep it for paper mache. Cover the whole thing with masking tape.

We used a full sized rake handle as the sword handle. It is around four feet in length. Whittle a point on one end then hammer it right into the sword. Leave about two feet of handle extending out.

Then beef up the handle by wrapping it with paper and duct tape.

Then we wrapped it in plaster cloth. This is optional. You can wrap yours in paper mache when you do the blade of you can leave it and try painting it later.

Okay! Let's continue with the making of this sword - You can also watch the video tutorial below

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