How to Make a Cosplay Double-bladed Lightsaber
Use a laser cutter to rough cut plexiglass blades. I ordered mine from Ripper Blades.
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Using a belt sander, bevel then round off the edges.
2
Hand sand using a fine grit sandpaper.
3
Buff with a drill attachment and buffing compound.
4
For added detail, use a round Dremel bit to carve electric lines into your blades.
5
Select various PVC pipe fittings from the hardware store.
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Assemble your PVC hilt and place two LED flashlights inside.
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To keep the PVC pieces stable, cut a piece of Worbla Mesh Art. Its embedded fibers will make a sturdy hilt.
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Heat Worbla Mesh Art and apply. Reheat as needed for details.
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Add details using Worbla Black or Finest Art.
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Trace templates and cut out with sharp scissors.
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Heat and apply. Other Worbla adheres to Mesh Art perfectly.
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Using a wooden skewer, press in some faux rivets.
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Seal Worbla with two coats of Flexbond.
15
Base coat hilt with your favorite black acrylic.
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Apply Rub ‘n Buff for a metallic sheen.
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Wrap with leather strapping and secure.
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Happy cosplaying!
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