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Kingdom Key - Build Log

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Postby Soul » Wed May 02, 2012 8:45 pm

So I am starting work on a Kingdom Key for my cosplay and I thought it would be a great idea to share the process with you all, get your feedback, and help anyone else out there who is looking for a guide to building one!

Let's get to it!

Part 1: Design and Shopping

To start I took a couple of reference pictures from around the internet, but found that these two were the most use to me:

Kingdom Key itself:
Spoiler:

Sora with the Key:
Spoiler:


From the first image, you can see clearly the parts that would be needed for the key, the main "shaft", the key, the guard, and the other fiddly bits :P

From the second picture I was able to get the general size of the key. By rough measurement, the key was about 5/9ths of Sora's height, so to make a key to scale with myself, I would need 5/9ths of my height, which comes out at around 1m (not including the chain).

So now I have a rough idea of what I am looking for I got my shopping list:

    1m Long Dowel/Broom Handle
    Foam board (key and guard)
    Silver foam safe paint
    Yellow foam safe paint
    Navy Blue paint
    Black/Dark Grey paint
    String (for grip on handle)
    Soup Can (wide round bit at bottom)
    Chain and Mouse Head

And this is what I managed to get:

    1" diameter, 48" long, wooden dowel - $6.99 (Home Hardware)
    Yellow Acrylic Paint - $1.23 (Dollar Store)
    Blue Acrylic Paint - $1.23 (Dollar Store)
    Dark Grey Acrylic Paint - $1.23 (Dollar Store)
    Metalic Silver Foam Safe Spray Paint - $10.99 (Michaels)
    23mm x 149mm x 301mm Flora Craft Foam Sheet - $5.99 (Michaels)
    30mm x 250mm x 301mm Flora Craft Foam Sheet - $8.99 (Michaels)

Total Cost: $36.65 (Not Bad!)
(P.S. I didn't get a chain/mouse head, you generally don't find these at craft stores, however look online, they are bound to be there somewhere. As for string, I have some lying around, same goes for soup can once I eat the soup :P)

You could probably save a lot on the silver paint, however I wanted a smooth finish for the key so opted for the more expensive option of spray paint, otherwise, just hit up the dollar store again, they have great bargains on crafty things like that. Also you could save on using wood instead of foam, however I don't have the tools to manage that so I had to go for this option.

Part 2: Beginning the Build

So now that I had all the parts I had to get the design right.
I mainly used image one from above for this and drew out the shapes that I needed on the foam blocks that I had got from Michael's. It took a few tries to get it perfect but once I had one perfect shape I cut it out and used it as a template for the other foam blocks.
Since the blocks are quite thin, I ended up buying another two of the 23mm x 149mm x 301mm and doubled them up to create a thicker guard for the key as it gives a more cartoon like look being slightly oversized.
Once I had all the pieces cut out I just had to glue them together and sand them down to perfection!

Step 1: The template for the guard
Spoiler:

Step 2: Cutting the template out
Spoiler:

Step 3: Glueing the two parts together
Spoiler:

Step 4: Sanded down and finished guard piece
Spoiler:

Step 5: The "Blade" of the key
Spoiler:


Now that all of the foam pieces of the key are finished I turned to look at how I was going to actually attach these to the wooden dowel that I had bought for the main shaft of the key. I also noticed that there were some wider circular parts where the guard attached to the shaft at the top and bottom of the guard.
In the end I decided that I would glue the guard pieces to these circular bits and have the shaft go through them and either attach them with a lot of glue or find a way to screw them in place.

After much searching for the perfect items in my room to use for these, I ended up using an empty tuna can and an almost finished jar of peanut butter which fit perfectly after some cutting down.

I punched a circular hole the same diameter as the dowel through the top of the tuna can and it fit perfectly over the dowel with almost no need to glue it in place.

Step 6: Tuna guard
Spoiler:


I went ahead and did the same thing with the peanut butter jar but forgot to take some pictures. I will post them up when I do part three of the build though!

That's as far as I have got at the moment, the next step is to go ahead and glue everything to the shaft of the Keyblade. Once that is done I am going to cover all the foam parts in paper to get a smoother surface and then its time to paint the key and I am finished!

Stay tuned for the last two parts of the build!
Last edited by Soul on Sun May 13, 2012 11:19 am, edited 4 times in total.
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Postby Soul » Wed May 02, 2012 8:47 pm

Reserved in case of post limit!
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Postby SiguusaEcho » Wed May 02, 2012 10:36 pm

Looks like it should be coming along nicely :3 Now I want to make my own WIP thread! ...But I suck at posting WIP pics and all =( Best of luck to you on this project!
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Postby Soul » Fri May 04, 2012 2:03 pm

SiguusaEcho wrote:Looks like it should be coming along nicely :3 Now I want to make my own WIP thread! ...But I suck at posting WIP pics and all =( Best of luck to you on this project!


You should totally do a WIP thread! You could get someone else to take the pics while you make it.
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Postby Momimochi » Fri May 04, 2012 4:11 pm

Waitwhat. You're going as Sora? Ho, I be looking forward to that. (Only ever seen girls around 5'3-5'6 cosplaying that shota)
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Postby Soul » Sat May 05, 2012 12:26 am

Momimochi wrote:Waitwhat. You're going as Sora? Ho, I be looking forward to that. (Only ever seen girls around 5'3-5'6 cosplaying that shota)


:P no I am doing Roxas, I just like the kingdom key lol
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Postby Soul » Sun May 13, 2012 11:20 am

Part 2 is up!

Look at the first post, I added it in. Two more parts of the build to put up later so stay tuned!
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Postby norimaki » Sun May 13, 2012 1:25 pm

Wow this is pretty helpful when I'm looking for stuff to make weapons out of...didn't know where to start till I read this xD

and lol you are so resourceful. (tuna can)
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Postby Switch44 » Mon May 14, 2012 10:14 pm

That looks awesome so far. I just bought my supplies to build my Chakrams 3.0 for my Axel cosplay, going to be my third and best attempt XD


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Postby Kanra » Mon May 28, 2012 12:10 am

Looking awesome! I can't wait to see your Roxas! C=
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