Sword of Megatron Made From PVC
Introduction: Sword of Megatron Made From PVC
Hay guys this time I will explain you how I made any an iconic weapon from the movie transformer.The weapon I made is a sword used by <PERSON>.I decided to make this particular weapon because of its simplicity.its nothing but a fancy sword and you don't need to have any power tools.I used only PVC to make the sword.this was my first attempt to make something using PVC but I have seen a previous instructable which explains how to make a robot fish using PVC so that instructable inspired me to do this one.PVC is very easy to get and I am only using leftover pieces to make the sword.We don't need long or particular sized pieces for this project do its very easy to get all required materials.we also need pvc cement and cutting tools sand paper for this picture 1 shows all different sections of a sword take a look at this picture before reading below steps.picture 4 is only half scale drawing of the original model all other drawings are same size as the sword
Supplies
PVC pipe
PVC cement
Hacksaw(jewelers saw if available)
File,sandpaper
Screws
Tile filling
Paint
Step 1: Making Blade
So in this step I will explain how I flatned pvc pieces and how I made the Blade part. I am using 3/4 inch pipes but size doesn't matters since we are going to cut them to make flat Pieces.Keep pipe length below 10 cm this way it will be easy to cut and flatten them.If you use a single long piece to make the Blade it won't be strong enough to hold straight with out bending.My Blade is 42cm I cut 12 PVC pieces ranging from 10 to 6 cm long.To flaten these pieces PVC draw a straight line on the surface of it from top to bottom.Using a hacksaw Blade cut through the line this way you will get a Straight cut then heat the PVC from an open flame till it become soft while doing this do not place it directly on the flame because it will burn the pipe leaving bubbles and burn marks,so keep it above the flame and after a minute it will be soft enough to flaten.place this hot soft piece on a flat surface and open the PVC using along the cut.using a flat wooden panel press and hold it tight untill it become a flat piece.hold it for couple of minutes and it will be hard enough to stay flat.its important to have to flat surface to press the PVC otherwise pipes won't be flat and smooth any cracks or bumps on the pressing wood surface will be copied to the PVC panel.after cooling cut the width to 5 cm then use a metal file or a sand Paper to make edges straight and smooth.if its not straight it will be hard to Glu them together or there will be gaps in between the layers.Sand the panels before sticking them otherwise the bond won't be very strong do this for all required pieces.Next step is to Glu them to make a Blade I used PVC cement for this,some things to take care while Gluing is first you need to clean the edges and cut the flat piece as straight as possible Glu half of the first piece to the half of second piece and glu the third pieces half to the other half of second piece and repeat the steps. For the beginning and ending side cut and Glu suitable sized pieces.use clamps or weights to hold while the glue is drying.PVC cement bonds slowly but permanently.My sword Blade is 42 cm long but always make it a little more longer so we can cut it straight and sand ends smoothly.i will explain about the black part in 4th step
Step 2: Making Flared Tip
Next we need to make the bottom part use the above drawing as a reference when cutting required pieces.to avoid wastage of material i cut the pieces only to required size.It was hard to make a big two layred flat panel to cut out the Flared Tip.I made this in three separate parts and later glued them together (see the pictures)draw the design on the panel and cut it using a hacksaw Blade thinner Blade works better because of its angle But I was not able to cut it through the markings so I filed it along the lines then sanded to smooth out the edges.I made two tips of the sword separately the same way.<PERSON> Gluing the parts together I sharpened the Blade using a file.i was not actually making it sharp but trying to give it a sharp Blade look.to do this mark 1cm along the edges of the Blade and the Flared tip.mark only where the Blade needs to be sharpe,places where we will be sticking the parts together should be avoided.Use a file for sharpening,sand paper also works but to get a straight sharp angle you should use file. 819