Warhammer40k Chaos Raptor Chainsword

[NoxRocks]

Let me start by saying that I know nothing of Warhammer. A friend wanted me to make this, so after finishing my Deathstroke costume I started. He's a HUGE fan of Chaos, and I liked this design, so I picked this version.

This is also my first time working with MDF, so it's definitely been a learning experience.

Starting off with a template I whipped up from this picture:



Took it to FedEx and had a few copies printed(Keyboard for scale!):



Now that I look back I think I could've probably made the body portion extend all the way up to the top, but this made shaping the top MUCH easier. Lots of waiting while the glue dried..



I put all the pieces together after some rough cuts, and still have some more parts to cut out, but I wanted to get a couple pictures.



After I cut it with a jig saw I sand/shape the pieces, then lather the open edges with super glue to harden them up. Rough sand that, and then apply the bondo.



I have a TON of sanding in my future, but it'll be worth it!

 

[NoxRocks]

Well, I went to a convention October 2-4th, and I've been sick.

I did get some work done today though.

Today I redid all of the teeth, and added the main section to the body. I originally had a "tooth" shaped, but after looking at the whole picture it seemed small, so I decided to knock them out!

I've also begun shaping the top portion of the sword.

VERY happy I decided to purchase my belt/disc sander instead of a mini belt sander. This thing is magnificent.

Oh, and clamps. I feel like I can never have enough.

Anyway, picture of progress:

 

[NoxRocks]

After looking at the edges of some of the MDF I quickly realized that it wasn't smooth enough for me, and I wanted to try to find something better.

I was previously using super glue to seal the edges of the MDF, but it became a chore, and I ended up having to fill tiny holes with spot putty..

I scrapped the super glue and decided to try using only spot putty, but that required a couple coats, and more sanding than using super glue/putty..

Eventually I found a random thread online that suggested using wood glue watered down 1:1. I was skeptical because I know water destroys MDF, but it works fantastic. I did 2 thin coats with about 15 minutes of dry time in between and after, and it sands like a dream. I used a 320 grit piece of paper and it's super smooth. So, if you're like me and can't find an way to seal edges of MDF I highly suggest giving it a try!

I did it to all the teeth of the blade today:



TLDR: Wood glue thinned 1:1 with water is an amazing edge sealer for MDF after a couple thin coats.

 

[HighlanderFX]

Wow that's brilliant. I've been trying to find a good solution for sanding MDF and the thinned wood glue sounds perfect.

The chain sword is looking pretty sick! Does your friend just want this as a cool prop to have for display or is he doing the rest of the raptor?

 

[NoxRocks]

Wow that's brilliant. I've been trying to find a good solution for sanding MDF and the thinned wood glue sounds perfect.

The chain sword is looking pretty sick! Does your friend just want this as a cool prop to have for display or is he doing the rest of the raptor?

I believe he's just wanting a display piece.

I don't know if he's the costume type, but he was showing me all kinds of videos and pictures of others' armor, so we'll see

 

[Ikras]

That's looking great. Love the look of all the chaos stuff.

For first time working with MDF it's certainly not showing.