Zelda Master Sword Build from Twilight Princess

[Jue]

Hi Guys,
I've been coming to this place for quite some time now, I love seeing the amazing things people are able to make, so I finally decided to try build something and share myself, and obviously what better place to start than with the Master Sword (I like a challenge)!
Twilight Princess is easily my favourite game in the series, I just love the darker, grittier, less cartoonish style and the more intricately designed items. If this goes well I'd love to build the collection until I have the whole inventory from TP.

I'm working off this picture, pretty sure it's from the Hyrule Historia:

I worked several days straight getting these 3D models to a point where I was satisfied.


I had initially intended to get the crossguard 3D printed, unfortunately I missed my opportunity to use a 3D printer I had access to, and turns out getting it commercially done would cost a fortune, so it looks like I'll be doing this the old fashioned way.
As in my model I really like the idea of having a translucent gemstone in the middle of the hilt that glows, rather than in the art and in the game where it just seems to be gold, so i'm gonna see if I can work in some LEDs, all depends on whether I have enough space in the hilt and crossguard to fit a battery and wiring etc.

Anyway, I'll keep posting and adding photos as I progress, enjoy!

 

[Jue]

I've more or less finished modelling the hilt. Just built up a framework with cardboard and did the rest with modelling clay. Will refine and smooth it as best I can and then try make a cast of it.

 

[stigmorgan]

Dude this is brilliant, I love zelda and I have the hyrule historia book, if you need images im happy to have a look through and find some for you.

 

[psiewert]

This is awesome! I hand make knives as a hobby and would love to help if you're interested.

 

[sonicfreak04]

will resin casts of the hilt be for sale?

 

[Jue]

Dude this is brilliant, I love zelda and I have the hyrule historia book, if you need images im happy to have a look through and find some for you.

This is awesome! I hand make knives as a hobby and would love to help if you're interested.

Thanks so much for the support! I'll keep these in mind if I ever run into trouble.

will resin casts of the hilt be for sale?

Sorry but I'm afraid not, this I just a personal project I'm trying to quickly bang out while I happen to have some free time.

 

[Jue]

Got started on making the mould. Unfortunately I underestimated how much silicone I would need and only had enough to do one half, so I'll have to wait until I can order more before I can finish. In the mean time I'll remove the framework and work on hollowing out the model in preparation for creating the mould on the other side.
I'm pretty happy with how it turned out though, especially since it's the first time I've done this sort of thing:


I've been experimenting with some translucent polymer clay for the gemstone on the hilt. Shaped it, baked it and sanded it smooth, and it came out pretty nice. Also looks pretty awesome glowing with a light shining behind it.


Not sure how I feel about it being neon/fluorescent yellow though. Now I have the shape down though I can make a cast and experiment with some coloured resin perhaps in a more subdued colour.

Also started making the gold details on the hilt and blade, cutting them out of brass sheet metal and sanding and filing down the edges. It's very fiddly, pointy, fingertip-destroying work, but I'm liking the results.
I'm using this for the Triforce on the blade as well. In the games, artwork, and replicas it seems to be etched/engraved in the blade, but personally I like the idea of having it embossed and gold.

 

[Jue]

Been a while since I last posted an update, sorry about that, my free time ran out much sooner than expected, so I've only been able to work on this every now and then since.
Finally got my mould finished and was pretty thrilled with how it turned out.


Getting a good cast from it though was much harder than expected, ended up with several miscasts. There was a lot of trial and error with how much resin was needed to fill the whole mould and how to best distribute it throughout to get into all the corners and intricate bits.
Eventually got out two casts that were...well I wouldn't call them good exactly, but easily usable. each just has a few bits an pieces that need filling in with some putty which will then be filed and sanded back, which you can see I've just begun doing.

 

[Jue]

Been quite some time since I've been able to do some more work on this, but I've finally gotten back into it.
Turns out my original clay model wasn't nearly as symmetrical as it seemed, or perhaps my mould was just bad, either way the 2 halves didn't line up all that well so a lot of filler material had to be added, but after lots of grinding with a rotary tool I was able to even everything out and I'm pretty happy with the result



In the base I embedded a threaded plumbing fixture.


Also found a piece of steel pipe that's the perfect length for handle and is threaded on each end, so the crossguard can screw right on and so can the pommel when I make it.


There's still a lot more fine sanding to do, but all in all I'm pretty thrilled with the way it's looking!

 

[WilsonUndead]

I'll be keeping my eye on this, I plan to make one too but was trying to think of the best way to make the hilt.

 

[Jue]

After I'd sanded down the hilt a bit more I gave it a few coats of paint to help smooth out the surface a bit, fill in a few of the smaller scratches and help highlight any major defects I need to fix. Thankfully the surface came out pretty even.



Built a few more of the gold accents, once again out of brass sheet. Just a matter of cutting and bending a few pieces to shape, soldering them together, and then filing and sanding any excess material. These pieces are the caps at the top of the hilt where it meets the sword and the accents that run up the blade.
Also made the jewels to go in the middle. In the end I decided not to go with the translucent clay, instead I made a quick model out of cardboard covered in some plastic gap-filler, made a silicone mould out of it and filled it with clear resin tinted with a little yellow paint. I found a thin torch that fits nicely into the handle (i'm not going to bother trying to rig up batteries and LEDs) and it lights up the jewel really well.



I was bit torn about how to colour the gem setting in the centre. Some swatches of the gold paint I had made it clear that the setting wouldn't match the colour or finish of the brass pieces I'd made. I considered covering it in some gold leaf but thought that would make pretty obvious the uneven surface of the resin cast. In the end I decided to remake this out of brass as well to go over the top. This would also make it easier to engrave the jewel setting.
You can see in some of the concept art some runes present. I can't find anywhere that tells what it says (I don't think it says anything really, just random runes) and i'm not too bothered with accuracy, so I engraved (poorly) in TP Hylian "Blade of Evils Bane" around it!

 

[stigmorgan]

After I'd sanded down the hilt a bit more I gave it a few coats of paint to help smooth out the surface a bit, fill in a few of the smaller scratches and help highlight any major defects I need to fix. Thankfully the surface came out pretty even.

View attachment 602161

Built a few more of the gold accents, once again out of brass sheet. Just a matter of cutting and bending a few pieces to shape, soldering them together, and then filing and sanding any excess material. These pieces are the caps at the top of the hilt where it meets the sword and the accents that run up the blade.
Also made the jewels to go in the middle. In the end I decided not to go with the translucent clay, instead I made a quick model out of cardboard covered in some plastic gap-filler, made a silicone mould out of it and filled it with clear resin tinted with a little yellow paint. I found a thin torch that fits nicely into the handle (i'm not going to bother trying to rig up batteries and LEDs) and it lights up the jewel really well.

View attachment 602162 View attachment 602163 View attachment 602166

I was bit torn about how to colour the gem setting in the centre. Some swatches of the gold paint I had made it clear that the setting wouldn't match the colour or finish of the brass pieces I'd made. I considered covering it in some gold leaf but thought that would make pretty obvious the uneven surface of the resin cast. In the end I decided to remake this out of brass as well to go over the top. This would also make it easier to engrave the jewel setting.
You can see in some of the concept art some runes present. I can't find anywhere that tells what it says (I don't think it says anything really, just random runes) and i'm not too bothered with accuracy, so I engraved (poorly) in TP Hylian "Blade of Evils Bane" around it!

View attachment 602173 View attachment 602164 View attachment 602165

Dude this really is looking stunning.

 

[KevinBGoode]

Stunning work!

 

[Jue]

Dude this really is looking stunning.

Stunning work!

Thanks very much guys! It's taking me a lot longer than I initially thought but I'm enjoying the challenge and the results!

 

[ThePropBox]

Quite frankly I have to say that this might become THE Master Sword replica!
I've seen quite a few of those but never one with that attention to detail.

Keep up the good work!! :thumbsup

 

[Jue]

Quite frankly I have to say that this might become THE Master Sword replica!
I've seen quite a few of those but never one with that attention to detail.

Keep up the good work!! :thumbsup

Oh wow, thanks a lot!!! That means so much!

Spent this week working on the pommel. Built up a cardboard frame work around the end of the handle, filled and covered it with putty and ground and sanded it back. Did the same with the 'X' shaped detail at the very end and attached the two.



Gave all the hilt components a few coats of primer and a good sanding back and I'm satisfied enough to say this part of the build is finished! (well, mostly satisfied, partly just really really sick of sanding things! ) I'll leave the painting and attaching the brass highlights until the end of the build when I have all the components ready for assembly. Next task, the blade!

 

[ThePropBox]

GREAT STUFF! The hilt looks totally spot on.
Are you planning to wrap around some leather cords/bands around it? I guess you are but I'm just curious
Sick of sanding? For some weird reason that's my favourite part of any build. Dunno why, it just is haha.

Not sure if I missed it but the blade is going to get made from real metal?

 

[Jue]

GREAT STUFF! The hilt looks totally spot on.
Are you planning to wrap around some leather cords/bands around it? I guess you are but I'm just curious
Sick of sanding? For some weird reason that's my favourite part of any build. Dunno why, it just is haha.

Not sure if I missed it but the blade is going to get made from real metal?

Haha, I just don't think I have the patience for sanding, I can never get it as perfectly smooth as I'd like and then I get fed up and frustrated!

Definitely going to wrap the handle, unsure in what way just yet though. In-game and in the artworks it looks like multiple strips sort of braided and spaced apart, personally I think it might look better with a single thicker strip wrapped tight along the whole handle, i'll just have to see how I feel at the time.

As awesome as it would be to make the blade out of metal I have neither the skill nor the budget to do that, so i'll just be making it out of wood and painting it. If I ever felt like it I could always come back later and give a metal blade a go and swap it out, but i'm happy with wood for the moment. It's not meant to be practical or functional, just something to hang on my wall and look awesome, and i think it'll accomplish that

 

[ThePropBox]

Same here but the process is so relaxing for me and IF I finally got it as smooth as I wanted it to be I couldn't be happier. Holy cow it seems I got a sanding fetish hahahaha :lol

Yeah I just looked up some images of the sword and it seems there are several versions of the handles grip.
One got some X-shape going on with the cords, other ones got wrapped straight up in it. Not sure if the swords appearance changed with the time.

Making it from wood certainly has its advantages of not needing an anvil certain blacksmithing stuff! And all the engravings can easily be done.
Aaaah I cannot wait for you to finish it up!

 

[Jue]

Managed to smash out the sword construction a bit quicker than I expected. Just traced the pattern onto a piece of MDF, then discovered my Dremel had a handy spiral-cutting-bit which made pretty easy work of cutting the shape out. Then I just used some electric sanders and my Dremel again to clean up the profile and to bring the edges to a point.
With a little extra sanding around the base it fit really well into the hilt. Pretty damn happy with how its looking



I'll start painting everything soon. I was going to wait until I had everything made, but the only things left are a few more brass highlights, and as they're the last things that will go on there's no rush. It'll still look awesome with what I've currently got.