SWORD KIT ASSEMBLY INSTRUCTIONS

PART LIST:

• 1x Blade tip

• 1x Blade mid

• 1x Blade base

• 1x Cross guard

• 1x Handle

• 1x Pommel

TOOLS AND EXTRAS:

• 1x 6mmx1m threaded rod for full size sword

• 1x 4mmx1m threaded rod for 50% size sword

• 2 Part epoxy/ Strong resin adhesive

• Car filler/ Any other filler or smoothing product (I use Upol-Smooth car body filler)

• Sanding equipment (Recommend using a Dremel and some sanding blocks)

• Filler primer/ High build primer

• Primer/ Paint/ Protective lacquer

• Drill

• Files and Rasps

  
  

STEP 1

Roughly sand all the components individually until the majority of the layer lines are gone.

I use my Dremel with a 60 grit drum to do this, quick and light passes are key to keep it consistent.

STEP 2

Once most of the lines are gone use sanding paper and blocks up to 240-400, not too important, just to clean up the rougher sanding.

STEP 3

Next you will want to use rasps and files on all the sockets and fingers that connect the parts together.

They need to easily fit into each other without being too loose that they can move.

Take your time with this step, its quick and easy but if you force them in they can break off in the other part.

In case they do get stuck and you are worried about breaking it, just leave it connected and close the gap as best you can.

STEP 4

Run the 6mm/4mm threaded rod completely through the parts individually.

I use my drill chuck to lock onto the end of the bar and spin it through, you can do it by hand but it hurts and takes ages.

Remove the bar when finished and do it on all the parts making sure it fits through them all completely.

STEP 5

Using the 2 part epoxy you will want to connect the 3 blade sections together whilst running the rod through them.

The epoxy is fast acting and you will NOT be able to undo it if you mess it up, so you need to be quick!

ORDER OF OPERATION:

1. Threaded rod in the drill

2. Mix up the epoxy resin about the size of a decently sized coin each blending them together

3. Spread some epoxy onto the end of the rod and about 10cm up

4. Run the bar through the blade base from the cross guard side until it is flush with the hole on the other side

5. Put epoxy in the hole and connecting face then attach the middle section of the blade, again running the bar until it is flush

6. Again put epoxy in the hole and connecting face then attach the blade tip and run the bar through very slowly and carefully until you feel the bar hit the end of the channel.

If you go too far it will snap the blade so go until you feel the blade want to spin with the bar.

7. Push any extra epoxy into all the gaps between the sections then wipe off any extra resin that has seeped out the best you can.

STEP 6

Once the epoxy has dried (Roughly 5 mins) sand back whatever is left of the resin that has seeped out between the gaps

Car filler and paint does not attach to the epoxy very well so you want to clean it up best you can.

STEP 7

Next you will want to use car filler to smooth out the blade, cross guard and pommel.

(Roughly a golf ball size of filler to a couple of peas of the hardener.)

Force it into the gaps and anywhere on the cross guard and pommel that has layer lines still showing.

Takes 10-20 min to dry unless you add more hardener but then you have less time

STEP 8

Use the dremel or rotary tool to knock off all the big blobs and chunks that are not needed then use sanding blocks and paper to sand it back smooth.

60-400 grit

STEP 9

Repeat step 7 and step 8 until you are completely happy with the surface of the sword.

STEP 10

Use filler primer on all the parts and sand them back (400+ grit) to fill any tiny holes and further smooth the finish.

Repeat until satisfied.

STEP 11

Prime all the parts.

STEP 12

Attach the cross guard and handle onto the sword, then check if the pommel can fit on the end without the rod stopping it.

If the rod is too long mark it and cut it down to length.

STEP 13

Use epoxy resin to attach the blade to the cross guard, then the handle and pommel.

(Try not to spill any outside the connecting hole)

Wipe off any extra residue.

STEP 14

Paint and protective lacquer layer.

STEP 15

Enjoy :)

If you have any questions feel free to ask I'm happy to help. Get into contact on Twitter, Instagram or TikTok @Verain_Armament

or message me on my website VerainArmament.com

Thank you for your time and good luck on your new weapon.