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Fai's Staff Tutorial
Published: 2011-04-09 09:07:28 +0000 UTC; Views: 50699; Favourites: 1423; Downloads: 397
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Description
Woo, here's the tutorial!Again, there are other ways to make this, these are just my methods!
In total this was a solid week's work, but spread out over several months around other things I had to do. Apart from the plastics, none of these materials or the tools used are hard to come by or expensive, and the casting plastic was not as horrible as expected.
Materials used:
- 8mm thick sheet of a light type of wood
- thin nylon thread
- wood glue
- thin, sturdy cardboard
- fun foam
- multi pupose glue
- wall filler (bought as paste in tube, but can also be bought as a powder, which lets you control its thickness for a smoother finish - will be using this for most layers)
- water clear polyester casting resin + dye
- tin foil
- PVA glue
- long wooden dowel, 20mm diameter (through preferably same width as the staff head)
- primer paint
- brass spray paint
- clear spray paint
- 1mm clear HIPS plastic sheet
- super glue
- transparent blue glass paint
The link to the pattern: [link]
It is not perfect, and needs to be adjusted while you work; the lower part where it connects to the staff is not entirely symmetrical.
Fai D. Flowright and his staff are from Tsubasa: Reservoir Chronicle by Clamp.
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Comments: 175
I have a question. Can you use a big amount of HIPs as a broach? Im planning a Fi costume and the broach for her is the big diamond. Im making the gold thing around the diamond out of fun foam, while the diamonds is made out of steyrene.
So also my question, is it heavier or lighter then easy cast resin?
Here is a reference picture:
[link]
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Yes, you can. The easiest way is to make it hollow, then you don't need much material either: cut out four triangles and glue them together with superglue into the broach crystal shape, and use transparant glass paint on the inside for the glowing blue colour, like I used for the crystal on Fai's staff.
I wouldn't recommend making a solid crystal, because HIPS usually comes in sheets. Casting that big a shape in resin would also be quite heavy and need a lot of resin.
Good luck!
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Wow, I promised my best friend that I would make her one of these for her cosplay! You are the best! <3
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This is so awesome. Thank you for sharing the process with us.
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This is fantastic! A great tutorial, too, and a very helpful stating point for me ^^
Btw, how much did this cost you overall? I'm trying to work out my budjet for this cosplay
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Hmm, I'm not exactly sure anymore as it was some time ago. It might have been around 50 to 60 euros, but I already had the tools and some of the materials. It also of course depends on the prices near you! For me the wood was comparatively expensive.
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Thanks! 
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nice tutorial on fai's staff and iam planned on cosplay as fai soon
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can i used your fai's staff tutorial for my fai cosplay
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Sure, that's what I made it for!
And thanks for your message.
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thanks and i will have pictues of my fai cosplay and staff on my da
and i will taking sewing class soon
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hi there! love your tutorial!
may i know what are the dimensions for your staff head?
i'm in the process of making mine and it seems too small :\
currently the width of my staff head is 55 cm on the first set of wing like thing...
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Thanks!
Mine is about 65 cm across from wing tip to wing tip, and 55 cm long from the very top (wooden tip) to where the staff head becomes the staff. Hope that helps! Good luck
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Thanks!
That helped alright ;3
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Wow. That's made with wood??? AMAZING!!!!
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Oh, one question. How do you print a picture bigger than the printer paper..? Sorry for the stupid question
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That's not a stupid question! It's rather a good one as I spent ages figuring that out too.. I don't know if there is an easy way, but what I did is cut the image (making sure the big image is exactly as large as the staff needs to be) into several overlapping parts which each fit on an A4 page. Tricky and annoying, but it worked..
Good luck!
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Oh by the way, awesome costume! :3
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you are amazing, this must be like some sign coming across this tutorial! thank you so much! I've just started on my fai costume!!
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Oh I do have a question though... How much casting resin do you recommend one would need for the gems? Is 1kg enough, or is that way too little?
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A kilo is waaay too much! 
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Ok, thank you! 
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Ooh, I bought mine there too! I got the kit with .5L of resin: [link]
Dunno if you've used casting resin before, but I hadn't and found it useful to get all the bits and pieces in one kit. You'd need to get dye and moulds extra.
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That's a very interesting tutorial! I've been planning n trying out some casting resin too.
Just a small question though, that wallfiller is basically plain plaster? Because I could probably buy a bag of plaster at the art store and try it out.
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Thank you!
I think wall filler is a bit more and a bit stronger than just plaster, but plain plaster could do the same job in this case - if there aren't very big gaps to fill. Not sure though!
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Okay thanks a lot!
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though I've said it already to you in person, here let it be said again: congrats! and it does look great in real life!
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You're welcome!
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Plywood? oh man i hate plywood. It's such a pain to sand and it always chips off tiny pieces even though its the strongest type out there
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