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Fai's Staff Tutorial by samhawkeye Fai's Staff Tutorial by samhawkeye
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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Daily Deviation

Given 2011-05-15
Fai's Staff Tutorial by *sam4uk Suggesters Words: It's great both as a starting point for making cosplay props, and also fantastic for more experienced cosplayers to kick up their prop making in quality and detail. ( Suggested by taeliac and Featured by shelldevil )
:iconavette:
Avette Featured By Owner Apr 30, 2014  Hobbyist General Artist
This tutorial is very helpful. I hope to incorporate your methods for another prop. Thank you for taking the time to explain how you made Fai's staff. I especially like how the gems look! 
Reply
:iconleleudk:
LeleuDK Featured By Owner Feb 3, 2014
Hi ^^
Thanks for the great tutorial.
I made a template in vector graphics, and a PSD file for printing a template in A4 paper format.
I have uploaded it to my profile. If you want, you could link it in the text of this tutorial, but please reference me at the link please ^^

leleudk.deviantart.com/art/Fai…
Reply
:iconketchupgirlx:
ketchupgirlX Featured By Owner Aug 20, 2013

Fantastic tutorial!

 

Now a silly question (because I'm new to cosplay): what did you use to cut the pine wood into that elaborate shape? Jigsaw?

Reply
:iconsamhawkeye:
samhawkeye Featured By Owner Aug 26, 2013
Thank you! And yes I did. I just have basic tools really.
Reply
:iconwatchherfly:
WatchHerFly Featured By Owner Jul 30, 2013
AHHH This is a great tutorial! I find it very insightful.
I might use this as a reference for a sword handle project.
What type of wood would you recommend? 

Reply
:iconsamhawkeye:
samhawkeye Featured By Owner Aug 7, 2013
Pine is nice to work with because it's light and soft, and over here that's the cheapest type of wood as well. :)
Reply
:iconmistress0812:
mistress0812 Featured By Owner Jul 13, 2013  Hobbyist General Artist
Holy shite, this is a lifesaver. After successfully building myself Sakura's bird wand, I volunteered to help a friend with her Fai cosplay (I got off easy and am going as Kurogane, so I just need a sword). I was having SO much trouble with the top, and now my problems are solved.

I'm using PVC piping instead of wood for the main staff (here in the USA it's hard to find dowels any longer than a meter) and foam board for the head and foot. I had planned on using those stick-on giant rhinestones for the gems, but your idea is brilliant. Model Magic (or paperclay, or anything similar, for that matter) works really well to smooth everything out too :)

Grah. I'm so happy that you uploaded this, and I really can't thank you enough. :iconbegplz:
Reply
:iconsamhawkeye:
samhawkeye Featured By Owner Jul 18, 2013
You're very welcome! :) And good luck with your project!
Reply
:iconmistress0812:
mistress0812 Featured By Owner Jul 15, 2013  Hobbyist General Artist
One question, though - would it be possible for you to just sort of sketch up the basic pattern you used for the center gem? I'm having a hard time coming up with something that doesn't have a shit-ton of gaps in it.
Reply
:iconsamhawkeye:
samhawkeye Featured By Owner Aug 11, 2013
I will when I have a bit of time - others have asked this as well ;)
Reply
:iconyukiangel51:
yukiangel51 Featured By Owner Jan 20, 2013
um where can i get the wall filler and is the tin foil the same as aluminum foil thx
Reply
:iconsamhawkeye:
samhawkeye Featured By Owner Feb 4, 2013
Any DIY store should have wall filler, or you could use regular plaster. And tin foil is aluminium foil yes!
Reply
:iconyukiangel51:
yukiangel51 Featured By Owner Feb 4, 2013
thx so much for the answer i was kinda stuck on the tin foil thing
Reply
:iconsamhawkeye:
samhawkeye Featured By Owner Feb 5, 2013
You're welcome! There's always google as well for when you get stuck and I've disappeared. ;)
Reply
:iconyukiangel51:
yukiangel51 Featured By Owner Feb 9, 2013
im dorry to ask but howd u enlarge the pattern
Reply
:iconsamhawkeye:
samhawkeye Featured By Owner Feb 22, 2013
That depends on the program you're using - you could probably find instructions via Google! ;)
Reply
:iconyukiangel51:
yukiangel51 Featured By Owner Feb 9, 2013
meant sorry
Reply
:iconyukiangel51:
yukiangel51 Featured By Owner Feb 5, 2013
haha true
Reply
:iconyukiangel51:
yukiangel51 Featured By Owner Jan 12, 2013
sorry bout askin so much question where do u get the transulent glass paint
Reply
:iconsamhawkeye:
samhawkeye Featured By Owner Jan 13, 2013
I bought it online, but don't know where exactly. You can probably find a place to get it via Google. ;)
Reply
:iconyukiangel51:
yukiangel51 Featured By Owner Jan 13, 2013
ah ok
Reply
:iconyukiangel51:
yukiangel51 Featured By Owner Dec 30, 2012
say can i use gloss for the clear paint
Reply
:iconsamhawkeye:
samhawkeye Featured By Owner Dec 31, 2012
I think so - test it out on a small patch somewhere out of sight first to be sure!
Reply
:iconyukiangel51:
yukiangel51 Featured By Owner Dec 31, 2012
ok
Reply
:iconyukiangel51:
yukiangel51 Featured By Owner Dec 30, 2012
im really lookin forward to this im gonna make for me and probably my freind and plus im only 13 so it may be hard so ill sak for any questions
Reply
:iconsamhawkeye:
samhawkeye Featured By Owner Dec 31, 2012
Good luck, and feel free to ask questions ;)
Reply
:iconyukiangel51:
yukiangel51 Featured By Owner Dec 31, 2012
say whered u get the PVA glue
Reply
:iconsamhawkeye:
samhawkeye Featured By Owner Jan 6, 2013
PVA glue is white school glue, and you can get it pretty much everywhere they sell stationary. :)
Reply
:iconyukiangel51:
yukiangel51 Featured By Owner Jan 6, 2013
ah ok thx
Reply
:iconyukiangel51:
yukiangel51 Featured By Owner Dec 30, 2012
sorry i meant ask
Reply
:iconsamirashamseddin:
samirashamseddin Featured By Owner Oct 24, 2012
thank for help :la:
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:iconsamhawkeye:
samhawkeye Featured By Owner Nov 3, 2012
You're welcome :)
Reply
:iconarctic-lights:
arctic-lights Featured By Owner Oct 4, 2012  Student General Artist
Gah, this is amazing!! I'm trying to put together a Fai cosplay and this was perfect. Now, time to get wood...
Just a question, I'm relatively new to wood props, so how exactly would you cut the top part? Three times the same (except one of them)?
Reply
:iconsamhawkeye:
samhawkeye Featured By Owner Nov 3, 2012
Twice the same, then one with the curving lines connecting the individual branches/feathers! I found it easiest to do with an electric saw. :)
Reply
:iconarctic-lights:
arctic-lights Featured By Owner Nov 3, 2012  Student General Artist
Thanks!!
Reply
:iconwolfpainter:
wolfpainter Featured By Owner Aug 29, 2012  Hobbyist General Artist
Ughh.. This is amazing, and I would LOVE to make one for my Fai cosplay, but I have abselutely no idea where to get the materials from ;u;
Reply
:iconsamhawkeye:
samhawkeye Featured By Owner Sep 15, 2012
Any DIY shop would be a good start! :)
Reply
:iconlostdreamz82:
Lostdreamz82 Featured By Owner Aug 7, 2012
your staff looks amazing, I may try to tackle making his staff using this, thank you sooo much!! <3
Reply
:iconsamhawkeye:
samhawkeye Featured By Owner Aug 8, 2012
Thank you! And good luck! Looking forward to seeing the result ;)
Reply
:iconthe-loony:
the-Loony Featured By Owner Aug 3, 2012  Student General Artist
what a great tutorial!! =D
Reply
:iconsamhawkeye:
samhawkeye Featured By Owner Aug 3, 2012
Thank you! :)
Reply
:icondarkanimeaddiction:
DarkAnimeAddiction Featured By Owner Jun 17, 2012  Hobbyist Traditional Artist
I've always thought Fai was amazing.
and how amazing this is/you are scares me a little. Just a little.
Reply
:iconsamhawkeye:
samhawkeye Featured By Owner Aug 3, 2012
Aw, thanks ;)
Reply
:icondarkanimeaddiction:
DarkAnimeAddiction Featured By Owner Aug 7, 2012  Hobbyist Traditional Artist
No problem :)
Reply
:iconkebussy:
Kebussy Featured By Owner May 11, 2012
The crystal instructions have been extremely helpful. May I ask what brand of glass paint you used?
Reply
:iconsamhawkeye:
samhawkeye Featured By Owner Aug 8, 2012
Sorry for the wait! It was East Coast Fibreglass Supplies' ([link]) own brand.
Reply
:iconriluna:
Riluna Featured By Owner May 1, 2012
Geweldig! echt heel gaaf om te lezen hoe je het gemaakt hebt :D
Reply
:iconsamhawkeye:
samhawkeye Featured By Owner May 7, 2012
:D
Reply
:iconpeacherine:
Peacherine Featured By Owner Mar 4, 2012  Hobbyist Artisan Crafter
THIS IS SO RIDICULOUSLY INCREDIBLE. SERIOUSLY. I want to be Fai now, or even make it for someone else! Or make it just so I can carry it around at school or something! But, I make a much better Sakura than Fai, so I'll settle for admiring your beautiful model.

Amazing job, and thank you so much for sharing. I will definitely reference it when I make the staff Sakura's mother has for the convention I'll go to this summer~
Reply
:iconsamhawkeye:
samhawkeye Featured By Owner Apr 17, 2012
Thank you! :D And good luck with Sakura's staff ;)
Reply
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