How to Make a Keyblade Out of Metal

The right blade adds the finishing touch to a costume.

Kingdom Hearts is a game by Square-Enix that has become a phenomenon in many arenas. Not only is it a best-selling role playing game on multiple gaming consoles, it has spawned multiple commercially successful sequels. With its cast of memorable characters and flashy accessories, Kingdom Hearts has all the ingredients needed to draw the interest of "costumed play" (cosplay) enthusiasts worldwide. It is no surprise that you can find costumed fans wielding keyblades at anime conventions from New York to Tokyo. A metal keyblade creates a spectacle that few forget and is fortunately well within the ability of most fans to create.

Things You'll Need

• Long aluminum-handled broom
• Rough grain sandpaper
• Fine grain sandpaper
• Black electrical tape
• Reference images
• Magic marker
• 1 Sheet tin
• Tin snips
• 2, .125 by 2-inch full rounded edge aluminum bars 10-inches long
• 2, .125 by 2-inch full rounded edge aluminum bars 6-inch long
• 2, .125 by 3-inch aluminum bars 8-inches long
• 1-inch diameter aluminum pipe 2 inches long
• 1.25" Diameter aluminum pipe 3 inches long
• 1-inch diameter aluminum pipe cap
• Metal epoxy
• 2 C-Clamps
• Newspaper
• Gold metallic spray paint
• 12-inch Aluminum chain
• 2-inch Aluminum disc
• 2, 1-inch Aluminum discs

Instructions

Handle

1. Remove the broom head from the broom handle by rotating it counterclockwise until it falls off. You should be left with an aluminum shaft approximately 5-feet long.

2. Scrape the surface of the broom handle with the rough grained sandpaper to remove the majority of the paint enamel which coats on the broom handle. Scour the surface of the threaded area to remove any rough areas. You can leave the threads since you will be capping the surface, but make sure they have no edges that will fray or snag.

3. Remove the remainder of the paint from the broom handle with the fine grained sandpaper. Smooth the threaded areas as well.

4. Coat the threaded area of the broom handle with metal epoxy and quickly place the aluminum cap over the glued area. Wait until the glue dries before proceeding.

5. Wrap 18 inches of the broom handle in black electrical tape, starting at the aluminum cap and proceeding upwards. Wrap the handle again, starting at the top and working down.

Key Teeth

1. Scale up the reference image of the keyblade's teeth to fill an entire printer page.

2. Print the teeth image on card stock. Cut out the outline of the image and tape it on the sheet metal.

3. Trace the outline of the key teeth onto the sheet metal.

4. Cut the sheet metal along the marker lines. You should take care near the angled cuts since they will be sharp.

5. Smooth out the edges and sharper corners of the teeth using the rough grained sandpaper. If needed, smooth them again with the fine grained sandpaper.

Handguard

1. Adhere the 1.25-inch diameter pipe over the aluminum cap using metal epoxy, Allow it approximately 30 minutes to dry.

2. Attach one of the .125x3-inch Aluminum bars to the 1.25-inch diameter pipe facing flat edge up by using metal epoxy. Use the C-clamp to keep the bar stable and in place until the glue dries. Repeat the process for the remaining bar. When complete, the bottom of the broom handle should resemble the letter T.

3. Place the 1-inch diameter metal pipe over the top of the broom handle and slide it down until it is approximately 12-inches from the bottom.

4. Attach the 6-inch long aluminum bar to the 1-inch diameter pipe with the flat edge facing out, resting perpendicular broom handle using metal epoxy. Use the C-clamp to hold it in place until the glue dries. Repeat the process for the other bar. When complete, the result should resemble a lower-case T.

5. Attach the 10-inch aluminum bar to connect both the upper and lower hand guard sections by using metal epoxy. Use 2 C-clamps to hold the bar in place until the glue dries. Repeat the process for the other side.

6. Cover the broomstick with newspaper, leaving the hand guard exposed.

7. Spray the entire exposed surface of the hand guard with gold metallic paint.

Finishing Touches

1. Attach the key teeth to the top of the broom handle by using metal epoxy. Make sure the teeth lie parallel to the hand guard.

2. Affix one end of the chain to the bottom metal cap using metal epoxy.

3. Glue the 2-inch diameter aluminum disc to the 1-inch aluminum discs to resemble a Mickey ornament.

4. Attach the Mickey ornament to the free end of the chain between the ears of the ornament using metal epoxy.

Tips & Warnings

• Wear old or work clothing when using metal epoxy. If you are attending an event, make sure that your weapon conforms to the safety rules before bringing it.

• You should always wear protective gloves and eye wear when cutting sheet metal.

References

• YouTube: metal keyblade fenrir kingdom hearts 2
• YouTube: How to make Sora's Keyblade
• Kingdom Hearts Wiki: Keyblade

Resources

• Epoxy Glue: Metal Glue