jackdoud
Sr Member
A friend of mine has a son who's into the current show Gokiager AKA Power Rangers: Super Megaforce. I'll admit I watched some of the original Power Rangers 15+ years ago but only vaguely new that it was still running. Well the kid was turning 16 and one of the presents my friend wanted to give him was a Gokai Red costume.
She's good with sewing but hard props aren't her strong suit. Bandai Japan has put out toy versions of the props so she ordered a set. The sword has all the functions, lights and sounds of the series but the size leaves much to be desired:
She found one guy who'd modified the blade, leaving the hilt and electronics intact:
Custom Workz: Kaizoku Sentai Gokaiger - Gokai Sabre MOD Month!!!
But didn't want to deal with an overseas commission on a deadline so she asked me to takle it.
I disassembled the hilt and found that there are a fair number of mounting points so attaching a new blade wouldn't be that difficult:
I started by making a template out of some scrap plastic:
Then cut the shape out of a piece of 3/16" MDF:
Next I cut out layers of worbla and sintra to create the blade recess:
After laminating the whole thing together I had a strong blade ready for shaping:
I did some rough shaping with a boxcutter and xacto knife to get it to fit the hilt:
I then alternated with a dremel and palm sander to smooth it down with a few coats of putty and primer:
A few coats of Krylon Aluminum finished the blade:
While the paint was drying I decided to stick some lead fishing weights into the hilt with some plumbers putty to try and balance it out a bit:
Install the blade and screw everything back together. I think it came out pretty good. I could have spent more time smoothing, shaping and filling but it's fine for what it is.
She's good with sewing but hard props aren't her strong suit. Bandai Japan has put out toy versions of the props so she ordered a set. The sword has all the functions, lights and sounds of the series but the size leaves much to be desired:
She found one guy who'd modified the blade, leaving the hilt and electronics intact:
Custom Workz: Kaizoku Sentai Gokaiger - Gokai Sabre MOD Month!!!
But didn't want to deal with an overseas commission on a deadline so she asked me to takle it.
I disassembled the hilt and found that there are a fair number of mounting points so attaching a new blade wouldn't be that difficult:
I started by making a template out of some scrap plastic:
Then cut the shape out of a piece of 3/16" MDF:
Next I cut out layers of worbla and sintra to create the blade recess:
After laminating the whole thing together I had a strong blade ready for shaping:
I did some rough shaping with a boxcutter and xacto knife to get it to fit the hilt:
I then alternated with a dremel and palm sander to smooth it down with a few coats of putty and primer:
A few coats of Krylon Aluminum finished the blade:
While the paint was drying I decided to stick some lead fishing weights into the hilt with some plumbers putty to try and balance it out a bit:
Install the blade and screw everything back together. I think it came out pretty good. I could have spent more time smoothing, shaping and filling but it's fine for what it is.
