Instead of Balthazar's sword, we decided to go with the Flame Blade. I may do a video on how we fully made it later, but to start we pulled
Dulfy's screenshot and made an outline. Hannah then used this outline to freehand the design onto a sheet of thin MDF board.
We pulled the MDF's board design in about an inch on each side so that the foam wrap we put around it could touch on any side.
She then traced this design onto the foam and cut it out. We removed the lit up spaces to fill with Plastizote. Hannah textured around these gaps with a rotary wire brush dremel tip to give it the burned stone impression.
Odd angle, but you can see how it is multiple layers of foam sandwiched together over the MDF, which has the LEDs glued to it.
Before gluing on the foam though, I had to wire it.
You can see one of the LED slabs in the first image, since I glued my LED strips down onto paper coated in ducttape so it could be attached all at once to the MDF core. The second shows the patchworking. I had a limited LED budget and had to piece together my scraps to fit within the slots. I programmed an Adafruit Feather to give them a flickering red glow.
Here it is fully constructed. I traced out the gaps with plastizote and filled in over the LEDs once they were glued down. some paper towel scraps helped diffuse the light, and I gave the plastizote a wash with red leather dye to help with the color. The on/off switch is hidden under one of the guards near the hilt.
Next was painting. I did a primary coat, wasn't happy, then went running the
Muddy Waters Cosplay to teach me how to paint.
Et Voilà. A lit up flame blade, all from foam, a pvc pipe, and some thin wood.
Here it is attached to his hip with the sword belt we constructed around it. It glows very bright and can be seen during the day and under spotlights as well.