Buster Sword

Mike SchroppHalloween, Projects 142 Comments

This past Halloween I decided that I wanted to go a little more all out on my costume than I had in years past. After a little time spent brainstorming I decided that I wanted to try and find a character that let me use my already messy fauhhawk spikey hair and incorporate it into a costume. With spiky hair as a requirement I quickly turned towards anime and video game characters, from there I further narrowed the list to Final Fantasy and settled in on Cloud Strife. I had played FF in the past and thought it would be perfect. Only one problem, my hair is black and Cloud’s is blonde. Then I quickly remembered that Zack also had awesomely spiky hair. That helped finalize my decision in choosing Zack Fair.

The real fun of getting to do this costume was getting to attempt to build a Buster Sword. I did a bit of research and looked around places on the web to see what I could find. I ran across some sites selling replicas for a couple of hundred dollars, but they were not full size. What’s the fun of having a Buster Sword unless it’s the full-size version? I figured out the scale of the sword and decided if I wanted a relatively accurate Buster Sword I was going to have to build it myself from scratch.

I originally set out with the intention of building two swords, the first would be a prototype and the second a more polished version. But due to time constraints I ended up just putting all the finishing touches on the prototype and rolling with it. The sheer size of a full scale Buster Sword meant that I needed to find a way to build it and keep the weight down so that I could actually wield it. I first thought of using foam board and an overlay and then moved towards a hollow wooden structure. In the end though I settled in on just buying a 2×10 8 foot piece of lumber and whittling it down.

After some initial testing for weight I determined that the single piece of lumber approach would yield a sword of the appropriate weight to wield. I busted out the reciprocating saw and cut out the basic shape of the sword blade.

Buster Sword Marked Up

Buster Sword Wood

 

I then moved to the edge of the blade and cut both sides at the appropriate angle and width to create a blade edge that matched that of a full scale Buster Sword.

Buster Sword Wood Profile

Buster Sword Wood Cut

 

Once I had the basic shape and woodwork done I moved to the most labor intensive task of the sword build which was the finishing of the wood. The more difficult aspect of using wood is that it’s hard to paint it and not have the grain structure show. After getting the wood itself to a decent smoothness I used some epoxy filler to fill in the knots and rough areas of the wood surface. I followed up by sanding the surfaces before I applied a base coat of varnish to seal the wood. After applying the varnish I resumed sanding and smoothing the surface. Once this was done the next step was applying a coat of primer to the surface and then resuming sanding. This priming-sanding-priming technique was done numerous times until I was final satisfied with the smoothness of the finish.

Primed Buster Sword Blade

Buster Sword Blade Primed

 

Buster Sword Blade Primed

Primed and Sanded Blade

After achieving a fully prepped surface ready for paint I experimented with a couple of different paint colors to try and achieve the right look for the sword blade. After a couple of coats of paints followed by some wet sanding I was able to achieve a finish that in most cases looked almost metal like. Enough to fool most at least.

The next step following the sword blade was moving onto the handle and hilt of the sword. In testing out the weight of the sword and the balance I determined that I needed to have more weight near the handle to balance the sword out better. For this reason I ended up using a block of aluminum instead of a lighter piece of wood. I purchased a scrap cutoff of aluminum from a metal shop for cheap ($5) and then using a drill press drilled and tapped the holes needed for the handle itself, the attachment points to the blade and the 5 decorative screws in the face of the hilt.

Buster Sword Hilt

Finished Buster Sword Blade

 

Buster Sword Hilt

Finished Buster Sword Hilt

I sanded the block of aluminum with many steps of progressively finer sandpaper to achieve the metal finish that looked best with the sword. The handle I ended up using was a scrap piece of electrical conduit tubing from a hardware store. I cut it to the correct length to match the sword at full scale and then inserted it into the aluminum hilt. The handle inserts into the hilt with a small amount of press to keep it from moving. It’s secured with the middle decorative screws on both sides of the hilt, which are longer and are drilled and tapped into the conduit pipe.

Using another scrap piece of aluminum bought from a metal shop I made two aluminum pieces for the handle, the one fit over the handle and butts up against the hilt while the other is capped and fit at the end of the handle with a press fit.

For the handle surface I ended up getting a cheap spool of leather lacing and wrapping the handle top to bottom with it to achieve the look of a leather-wrapped handle.

Buster Sword Hilt

Finished Buster Sword Handle

 

Buster Sword Handle

Buster Sword Handle Detail

The final portion of the assembly involved attaching the hilt to the sword itself. I was concerned at first that the weight of the wood and length of the sword blade would be too much load for screws to hold the hilt to the blade. So instead of using regular screws I found a couple of unused screws I had purchased for a gutter I had hung on my house. These screws are larger in diameter than regular screws and most importantly they are very long, about 6 inches. Just one of these screws was able to hold the hilt to the blade and support the entire sword without issue. I used 3 of them to ensure that I would have plenty of clamping force and load carrying ability. This allows the sword to be swung around without fear of it breaking.

The finished product came out better than I could have hoped, given that it was just supposed to be a prototype I’m very happy with how the overall finished Buster Sword looked.

Complete Buster Sword

Completed Buster Sword

The sword materials list and cost are as follows-

2x10x8 lumber- $6
Epoxy Filler- $6
Spray Primer- $6
Spray Paint- $7
Sandpaper- $8
Electrical Conduit Tube- Free
Aluminum Scrap piece- $5
Aluminum Scrap round- $5
Screws- Had
Spool of suede- $5

Total = $48
 
I worked with my lovely assistant and costume maker extraordinaire @thetinnishflash and built up a pretty respectable looking Zack Fair costume from pieces gathered at the local Value World thrift store.

The costume itself came out great! I’m not a super picky costume person so I didn’t worry about some of the exact details; I just tried to get it pretty darn close. The same thing can be said about my hair, and the Buster Sword. I know Zack has had a couple of different hair looks in the series so I kind of just went with a mix of what seemed to look decent. For the Buster Sword itself there are a bunch of versions that I know of- Crisis Core, Advent Children, FF10, Kingdom Hearts, etc. I decided to just go with a more original and toned down look. I was going to add the gold coloring and handle embellishments but when I got to the end I really liked how the sword looked as it was, so I ended up leaving it. While it’s not a spot on replica I think the look is close enough that most will easily be able to tell what it is.

The sword was a huge hit and everybody really liked it, I had a couple of people offer to buy it and many people took pictures with it. Not sure if I’m going to sell it to someone who more frequently cosplays Zack or Cloud or just keep it and hang it on my wall.

For correct scale reference to a person and for the sheer awesome geekout factor I had @thetinnishflash do some magical Photoshop work and take one of the photos of me in my Halloween costume with the sword and Photoshop me into a Final Fantasy background. Its silly looking, dorky, geeky and everything else and I love it.

Final Fantasy Buster Sword

Final Fantasy Buster Sword

 

Also here is a picture of me making a really goofy face with my hair still done up like Zack fair but out of costume holding the sword. It gives another example of the scale of the sword; it’s a little over 6 feet in length.

Buster Sword Scale

Buster Sword Size

 

 

Buster Sword Dimensions & Instructions

If you're interested in making your own Buster Sword and would like more information, then click the button below, and head over to the Total Geekdom Facebook page. There you can Like and follow Total Geekdom and request more detailed information to build your own Full Size Buster Sword

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Comments 142

  1. Not sure if you still look at this thread. Beautiful remake, would you please send me the measurements, spray paint color/brands, and did you cover the final paint job with a clear coat? My email is joeyugan@yahoo.com, thanks!

    Reply

    1. Thanks! I still keep up with the comments, even though sometimes it takes me a while to get to them.

      There is no clear coat, the final finish was as I left it from the two colors I used.

      Reply

  2. Hi I’m taking a shot, I know it’s been awhile since you posted, but I’m going with a Zack Fair costume this halloween and I’ve tried to find a decent buster sword on the web. Yours is truly amazing, and I was wondering if you’d have time to make another one? Please email vezinama@msn.com for pricing and details, thanks!

    Reply

    1. Sorry for the slow reply. I sent you an email with more info on the making of and dimensions in case you wanted to see what was entailed. Right now I’m currently a little back logged with projects and not working on another sword. I plan to make more of them and sell them going forward though.

      And thanks!

      Reply

  3. Wow, great job man. This is the best replica buster sword I have seen. I have a Final Fantasy collection, and this would really add to it. Could you please send me the detailed measurements? My email is brandone2x@yahoo.com. Also I saw that you have done commissions in the past. Could you please include in the email what you would charge to recreate this sword including your labor, materials, and shipping.

    Reply

    1. Email sent!

      Thanks for the compliments, the sword really turned out great. I’m not currently making any other swords in the next couple of months due to some other projects I have underway. If you’re still interested though and don’t need the sword immediately (next couple months) let me know and we can discuss getting one made.

      Thanks!

      Reply

  6. So cool! I’m this would be my first cosplay, I’m doing angeal and this would be just amazing! I was wondering if you could send me the measurements to Sinistraa71@gmail.com? I would really really appreciate it!

    Reply

  9. That is a very well done and awesome replica of both Zack’s and Cloud’s sword. I made my own version of the Buster Sword out of strong cardboard, wood, and paint, but it is no where near as sturdy looking or as sleek as yours ha-ha ^^. I was wondering if you might by chance take a commission for a copy of this sword? I know you said you don’t want to give up that one you already made. But I’d be willing to cover the entire cost of the project and shipping and everything! The fact that you made that under 50 dollars is amazing :D!

    I absolutely love Final Fantasy, especially Cloud. I went to Comic Con as him and everyone loved it. I’d just love to improve the sword from mine I simply made to really make an impact and just add the proverbial cherry on top of one of my favorite anime characters :)! I’d love a response and again well done. You really have made Zack, Cloud, and all the Final Fantasy fans really, really proud!

    Reply

    1. Thanks, appreciate it. 🙂

      I have actually done some commissions on other swords for people, but I don’t do them very often because the time investment to do the sword like this is so high. With my day job I just don’t really have enough time to build them for just the cost of materials. The swords I’ve built for others I’ve built with some cost in there for my labor as well.

      So yes, I do commissions. Usually for the cost of materials plus whatever labor time is involved.

      Thanks

      Reply

  10. That is the best wooden buster sword replica i have seen!!! Can’t wait to try to make my own 😉
    Could you send the detailed measurements and instructions to br_tos@hotmail.com

    I would be so gratefull!

    Reply

  12. Looks amazing. how much did you say it weighs? and can you send me the detailed specifications and instructions? My email is SebatariNobula@gmail.com. I made one from foam insulation, a wooden dowel and a bit (lots) of duct tape before, and my friend wants to make one eventually.

    Reply

  13. Looks amazing, How much did you say it weighs? and can i have the detailed specs, measurements, and instructions?

    Reply

  15. This looks amazing! FFVII is by far my favorite game and I’ve been wanting to attempt to make clouds sword and you sir have made the best replica I’ve ever seen 🙂 please send me the measurements and instructions as well because I’m looking for a cosplay sword and now that I’ve seen this I’m thinking why not make it 🙂 my email is cfinalfantasy7@aol.com

    Reply

  18. if there is ANYWAY that you could sell this exact sword to me, I wouldn’t mind paying $100 or possibly a bit more for it since you’ve spent $48 in materials. if not that exact sword, I wouldn’t mind commissioning one from you to be made if possible.

    If you’re interested, and we can keep the price around the $100 range (maybe max $150) then feel free to E-mail me at: cardona_domingo@yahoo.com

    Reply

  22. Good day sir! Seeing your sword inspired me to really push my plans on having one. This is such a perfect replica of Cloud’s in the classic FF VII. If you’re still active sir can you please send me also the full details (measurements, instructions,etc.) in my email? Mail’s markjoshuajacobe@yahoo.com. Thank you sir and may you continue on doing these stuff coz it’s great!

    Reply

  24. @totalgeek:disqus sir can i have the exact measurements of the sword? please? i hope you’re still active 🙁 if you do come across this comment. can you please send the measurements to : ralphchong29@yahoo.com . THAnks a lot!! AWESOME SWORD BTW! IT’s THE BEST I HAVE EVER SEEN~! 🙂

    Reply

      1. Thank you!

        It’s not that bad, I’ve got used to sending the measurements out to those interested. I’m glad others are able to build their own versions too. 🙂

        Reply

  45. This sword is fantastic, i’m trying to make my own (sourcing wood in the UK not easy). Is there any chance you could send me an email with some more detailed instructions? zandybm@aol.com

    Reply

  49. gorgeous sword bro, this page helped me and my dad with my angeal buster sword. we had no idea what we were gonna do when it came to attaching the handle to the blade but you gave us a few ideas. what type of wood did you use?

    Reply

    1. Thanks! Glad it could be of some help. 🙂

      The wood is just SPF (Spruce Pine Fir) that I picked up from Home Depot. Non-pressure treated.

      Reply

  52. Beautiful work, man.
    I’m looking to make a similar style sword of my own design, so this really helps with ideas of how to go about making it well.

    Reply

  53. Hey i’ve promised to go as cloud to a con in November, only problem is, i have no clue on how to go about making this. i have decent woodwork and building skills but if you could please send me some more specific details it would be greatly appreciated. monsta0masha@gmail.com

    Reply

  54. oh my god o.o it’s perfect! sorry if i ask, but i would like to know how much measures the diameter of the screws you used. and if the screws you used must be placed in the three holes under the handle xp sorry for my bad english, i’m italian. Thank you

    Reply

    1. Thank you!

      I don’t know exactly what the diameter of the screws were, but I do know that they were 7″ length gutter screws. They were threaded about 75% of the screw and they used a square drive bit. 

      You could probably get away with less screws, like two maybe, but I went with 3 for the strength.

      Reply

      1. Like you have understood i’m trying to make this awesome weapon myself. 
        if you could send me more descriptive instructions, I would greatly appreciate it! Including materials, please and thank you! you are saving my costume.    

        fndero.zero@gmail.com the screw you used is one of these? thank you for all!

        Reply

  56. Hey could you possibly make me this? For a decent price. LOL. I need it for a Cosplay Party I’m hosting in a month. And i sadly can’t pay over $120.

    Reply

    1. I wish I could build them for around that price. Unfortunately they take on average 15-20 hours a piece to build with all the prep work on the wood (sanding/filling/ sanding x3, sanding/priming x3, sanding/painting x3) then the machining of the aluminum and various other portions of the build.

      I’m not super picky when I build stuff for myself, I just kind of explore and test things out, but if I’m building something for someone else and they are paying me for it I’m a real stickler for details and having it be perfect, whether it be a computer, prop or any other commissioned project. 

      So unfortunately I can’t build them that cheap, there are just too many hours of labor needed.

      Thanks

      Reply

      1. Blasted. Lol. Alright, thanks for the info. By the way, if you took that to comic-con you’d have a mess of people for your sales XD

        Reply

    1. Yes, I do build the swords for people. Email me through the Contact Me button on the right side of the page and we can discuss further.

      Thanks

      Reply

  61. My fiancee would love to have this sword… but unfortunately i’m really not capable of making it. His birthday is coming up in April, would there be any possibility at all of you building the sword and selling it to me? I would pay you for labor (whatever you’d like to charge).

    Reply

    1. Well, I did plan on building another one at some point, so I started buying some materials a while ago. So I could probably build another one. 

      I’ll send you an email to discuss further.

      🙂

      Reply

    1. Sorry missing a couple of marks that would make it easier to identify. The breakdown is as follows-

      2″x10″x8′

      or

      2 inches x 10 inches x 8 foot

      Reply

  64. What colors of paint did you use, what brand, and how many coats? i want it to be as close to yours as possible when i do mine.

    Reply

  65. You, my dear sir, have my respect. I’m picky on details too, especially in FFVII. You just made the perfect replica.

    And being a total FFVII nerd, I almost want to say “DATE ME!” xD

    Reply

  66. About how much does it way and is balanced to feel lighter? Also, would it have been lighter if you used a foam rubber?

    It looks a little unwieldy, think galvanized (even though dangerous to sand/grind) would add more weight to the hilt to make it easier to handle. 

    Reply

      1. It weighs 15 lbs exactly. The hilt section is a chunk of billet aluminum to help balance out the feel of the sword. So a lot of the weight is placed by your hands and this helps make the sword feel balanced and easy to swing around.

        🙂

        Reply

    1. Thanks! I initially planned on using a table saw but the saw I had access to couldn’t cut the correct angle. So I ended up using a reciprocating saw and doing it freehand and then doing a little cleanup with a sander. It worked out really well. 🙂 

      Reply

    1. I’m somewhat fond of this first one I built but would probably consider selling it. I’ve also considered building and selling them, it’s decently labor intensive but it’s something I’ve considered since I’ve had a couple of people ask me if I make and sell them.

      If you want to contact me to discuss further you can email me using the Contact Me button on the right of the page. 🙂

      Thanks

      Reply

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