Making Of: Buster Sword (Part 1)

Ah, do you hear that? It’s an excuse to make an iconic piece of video game history without actually wanting to cosplay the character myself. Don’t mind if I do!

The commission for Cloud’s armor and the Buster Sword came through and I absolutely could not wait to get started. He wanted them to be durable so that he didn’t have worry about about them getting damaged during wear, so I decided to go with a foam core and thermoplastic shell. Since the Buster Sword was going to be the biggest user of materials and had relatively few fussy, rounded pieces, we decided to go with Wonderflex. It’s about half as expensive as Worbla but works best with flat pieces.

Here’s a step-by-step follow-along on how to proportion this oversized toothpick properly!

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