Silesti Makes

Build

Ever since I first saw Emily Blunt as Rita Vrataski, the “Angel of Verdun” climb out of the crashed drop ship with the massive sword, it was something I wanted to make. What I didn’t realise at the time – because Emily Blunt had my attention! – was that the sword is actually a broken helicopter rotor blade.

Before I go into MY build, I have to mention this instructable where I sourced the pattern, lettering stencils and STLs for the printed parts.. Thanks! Angel of Verdun Sword – Edge of Tomorrow Prop : 11 Steps (with Pictures) – Instructables

The build for this used 3D printed parts for the handle elements a wooden rod for the grip and layered EVA foam around a plywood core for the blade. The blade core was reinforced with a pair of 6mm threaded rods because that’s all I had to hand, but when I put them in place I was actually pleased I did it that way as the threads locked together and gave a much stiffer support than a solid rod would have done. One to remember!

The threaded rods were measured long enough to extend from the blade all the way down the inside of the handle to give full end-to-end support.

The plywood core was cut smaller than the EVA blade halves to give me space to shape the edge and back of the blade without worrying about exposing the wood. The flat elements were stuck together with contact adhesive and the threaded rod with hot glue for gap filling.

The handle dowel was drilled to accommodate the threaded rods and then I prepped and added the 3D printed parts which had gone through the usual sand, prime, sand, prime routine. With the printed parts in place and oriented correctly, I used 2-part epoxy to secure the handle to the threaded rod and the main body of the blade.

Finish

There are some key visual elements to this prop., the lettering on the blade, the UDF ID plate and the red stripe sprayed over. For the first two of these items I once again thank bwrussell for his work on the stencils and label design.

The edge of the blade is aluminium tape which works visually in a number of ways. Firstly.. it’s metal so it looks like metal! Secondly it’s possible to use paint and weathering differently on that surface which adds to the visual appeal and ‘sells’ the idea.

The blade was primed with black plastidip and the top coat is an acrylic anthracite spray which I deliberately over-sprayed onto the aluminium tape so that it could be rubbed back and give the worn look.

The handle elements had a silver base coat with a lacquer layer over the top and then a black coat of acrylic spray which I scratched back to give the well-used look. The ID label was simple printed onto metallic silver paper and stuck in place with spray-mount. The red stripe is simply a couple of swipes with a spray can.

After everything was in place it was rubbed back to bring the look together and we were done!

Music