Junior Evil Mad Scientist Chris came to us for help with what turned out to be a funny little (well, huge) cosplay prop project. The kind of project that starts off with a conversation that goes like this:
“You want to build what?”
“A giant sword for my costume for FanimeCon!”
“And when do you need it by?”
So, we got to help make a 64″ long replica sword, one of several from the flash game Epic Battle Fantasy 3 (which we had admittedly never heard of before), in what turned out to be kind of an interesting (if quick) project.
Chris drew up the outline for the sword in Inkscape, by tracing the outline of a bitmap drawing of the sword in a larger collection (where you can find this one in the top row, one third of the way from the left). We cut the outline on our CNC router from lightweight 3/4″ hardwood plywood— strong enough to not be floppy, yet light enough to be carried — and sanded the sides until it could be handled without creating splinters. We also sanded a slight bevel around the edges of the blade, so as to create the illusion of a sharpened edge without actually thinning it much around the edges.
Next, we needed to paint the sword silver. We had some silver spray paint on hand (left over from our 555 Footstool project!), but if you directly spray paint lightweight plywood, it tends to soak into the wood unevenly, dry slowly, and leave a finish that awkwardly highlights the grain of the underlying wood. Instead, we coated the sword with a fast-drying sanding sealer and allowed it to dry for two hours before getting out the spray paint.
In the mean time, we made the hilt details— what might count as greebles —by laser cutting two sheets of thin 1/8″ thick plywood on each side, in a shape slightly inset from the outline of the thicker plywood. There are two of these, one to go on each side of the hilt.
Once the sanding sealer had dried enough to gently sand, we test-fit the parts together. The photo above shows how the parts look after laser cutting and with the slick, yellowish finish that the sanding sealer gives to the plywood.
Next, we spray painted the body of the sword. Primer gray for the hilt section and metallic silver for the blade section, and allowed it to dry overnight.
Separately, we painted the laser-cut overlays black with black one-part polyurethane finish (the same type that we used for our ASCII art Tie Fighter project), and allowed them to dry separately.
In the morning, a little superglue attaches the newly-black hilt details, an old leather belt becomes some lashing details, with the help of a staple gun, and… it’s off to the show.
In case you’re interested, you can download a copy of Chris’s sword design here, as an Inkscape SVG file.
You can find more costume projects in our Halloween Project Archive.
Our friend Ben sent us this picture of his son’s “robot” costume:
…lit with, what else, EMSL surplus traffic light— kill your eyes —LEDs. It’s five series pairs of your LEDs pointed up inside the costume and down the sleeves so the light bounces around and positively pours out of every crevice – highly visible for trick-or-treating! There’s another two pairs, not lit in the picture, controlled by the momentary switches on the front panel for “turn signals.”
Thank you, Ben for sharing your project! And we still have just a few more of those eye-killing LEDs in the shop.
Here is what we heard, over and over last night:
“Whoa, is that a real— Holy crap, those are real pumpkins!”
Not as easy as we thought it would be, either. Nor as light. But here’s how to do it.
Halloween, one of our favorite holidays, is fast approaching. We’ve updated our Halloween Projects Archive once again to ensure that all of our Halloween projects are gathered together in one convenient location. If one of our projects inspires you to make something, we’d love to see the results in the flickr auxiliary.
The Great Evil Mad Scientist Laboratories Halloween Project Archive!
Halloween is one of our favorite holidays, and our collection of Halloween projects continues to grow. Every fall we update it to include our latest projects for the season. In the list that follows, we’ve organized dozens of our Halloween projects into categories: costumes, pumpkins, decor and food.
Last updated: 10/2015.
Well, almost— With a breath of new firmware, our Larson Scanner kit takes us on a trip to the late 1970’s.
In the old videos of electronic music pioneers Kraftwerk performing their classic The Robots, a prominent prop is the animated LED necktie worn by each member of the band. If you haven’t seen this, or it’s been a while, you can see it right here at YouTube. (Additional viewing, if you’re so inclined: Die Roboter, the German version.)
The Kraftwerk tie has nine red LEDs in a vertical row, and one lights up after the one above it in a simple descending pattern. And what does it say to the world? One thing only, loud and clear: “We are the robots.” Now, if you’re anything like us, the most important question going through your head at this point is something along the lines of “why am I not wearing a tie like that right now?”
The good news is that it’s actually easy to make one. And the starting point? A circuit with nine red LEDs and just the right spacing: our open-source Larson Scanner kit. With minor modifications– a software change and dumping the heavy 2xAA battery pack–it makes a pretty awesome tie. In what follows, we’ll show you how to build your own, complete with video.
Happy birthday to us! Evil Mad Scientist Laboratories is now three years old.
To celebrate, we’re rounding up our most interesting projects from this past year.
Quick projects and observations:
Simple LED Projects: