WARNING: Totally off topic --- Halloween prop DIY (lots of pics)
10-27-2007, 05:06 PM
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WARNING: Totally off topic --- Halloween prop DIY (lots of pics)
I was looking for something to do this weekend. My little girl got her Halloween costume, it's a ninja costume. She has the little robe, pants, mask, plastic sword... there is one thing missing, you can't get it here either because it is highly illegal in Canada... a NINJA STAR! I took it upon myself to provide her with a NINJA STAR to complete her costume.
Material used: an old metal plate (rusted scrap metal).
<img src="http://i132.photobucket.com/albums/q33/x1rider/nin1.jpg">
I started by cleaning it with an angle grinder and a wire brush.
<img src="http://i132.photobucket.com/albums/q33/x1rider/nin2.jpg">
Plate after cleaning.
<img src="http://i132.photobucket.com/albums/q33/x1rider/nin3.jpg">
I then used an ace/oxy torch to cut 2 squares out of the plate.
<img src="http://i132.photobucket.com/albums/q33/x1rider/nin4.jpg">
I traced a triangle on each square.
<img src="http://i132.photobucket.com/albums/q33/x1rider/nin5.jpg">
Then I cut the triangle from the square with a chop saw.
<img src="http://i132.photobucket.com/albums/q33/x1rider/nin6.jpg">
<img src="http://i132.photobucket.com/albums/q33/x1rider/nin7.jpg">
I used a grinder to form the sharp edges of the star and then "finessed" them with a bench grinder.
<img src="http://i132.photobucket.com/albums/q33/x1rider/nin8.jpg">
<img src="http://i132.photobucket.com/albums/q33/x1rider/nin9.jpg">
I then clamped both triangles together, as symmetrically as possible to weld the two together.
<img src="http://i132.photobucket.com/albums/q33/x1rider/nin10.jpg">
I then proceeded to TIG weld the two triangles together (six lap joints).
<img src="http://i132.photobucket.com/albums/q33/x1rider/nin11.jpg">
As you can see, I still need to practice my TIG welding. This one here is not too bad considering I started TIG welding a month ago and had never welded an inch in my life before.
<img src="http://i132.photobucket.com/albums/q33/x1rider/nin12.jpg">
I then used the drill press to make the center hole (removing as much weight from this sucker as possible).
<img src="http://i132.photobucket.com/albums/q33/x1rider/nin13.jpg">
Little efficiency testing (I just couldn't resist!).
<img src="http://i132.photobucket.com/albums/q33/x1rider/nin14.jpg">
Little trip to the sandblasting cabinet.
<img src="http://i132.photobucket.com/albums/q33/x1rider/nin15.jpg">
The little one's ninja costume is red and black, so I painted the star to match the costume.
<img src="http://i132.photobucket.com/albums/q33/x1rider/nin17.jpg">
<img src="http://i132.photobucket.com/albums/q33/x1rider/nin18.jpg">
All done, now you too can fabricate your own NINJA STAR. Unfortunately, my girlfriend threatened to ground the little girl for a week if she so much as touched the NINJA STAR!!!
One thing I learned is that ninja movies are BS, with all the effort and time needed to fabricate ONE of these, there is no way they would throw one every 10 seconds like in the movies!!!
Material used: an old metal plate (rusted scrap metal).
<img src="http://i132.photobucket.com/albums/q33/x1rider/nin1.jpg">
I started by cleaning it with an angle grinder and a wire brush.
<img src="http://i132.photobucket.com/albums/q33/x1rider/nin2.jpg">
Plate after cleaning.
<img src="http://i132.photobucket.com/albums/q33/x1rider/nin3.jpg">
I then used an ace/oxy torch to cut 2 squares out of the plate.
<img src="http://i132.photobucket.com/albums/q33/x1rider/nin4.jpg">
I traced a triangle on each square.
<img src="http://i132.photobucket.com/albums/q33/x1rider/nin5.jpg">
Then I cut the triangle from the square with a chop saw.
<img src="http://i132.photobucket.com/albums/q33/x1rider/nin6.jpg">
<img src="http://i132.photobucket.com/albums/q33/x1rider/nin7.jpg">
I used a grinder to form the sharp edges of the star and then "finessed" them with a bench grinder.
<img src="http://i132.photobucket.com/albums/q33/x1rider/nin8.jpg">
<img src="http://i132.photobucket.com/albums/q33/x1rider/nin9.jpg">
I then clamped both triangles together, as symmetrically as possible to weld the two together.
<img src="http://i132.photobucket.com/albums/q33/x1rider/nin10.jpg">
I then proceeded to TIG weld the two triangles together (six lap joints).
<img src="http://i132.photobucket.com/albums/q33/x1rider/nin11.jpg">
As you can see, I still need to practice my TIG welding. This one here is not too bad considering I started TIG welding a month ago and had never welded an inch in my life before.
<img src="http://i132.photobucket.com/albums/q33/x1rider/nin12.jpg">
I then used the drill press to make the center hole (removing as much weight from this sucker as possible).
<img src="http://i132.photobucket.com/albums/q33/x1rider/nin13.jpg">
Little efficiency testing (I just couldn't resist!).
<img src="http://i132.photobucket.com/albums/q33/x1rider/nin14.jpg">
Little trip to the sandblasting cabinet.
<img src="http://i132.photobucket.com/albums/q33/x1rider/nin15.jpg">
The little one's ninja costume is red and black, so I painted the star to match the costume.
<img src="http://i132.photobucket.com/albums/q33/x1rider/nin17.jpg">
<img src="http://i132.photobucket.com/albums/q33/x1rider/nin18.jpg">
All done, now you too can fabricate your own NINJA STAR. Unfortunately, my girlfriend threatened to ground the little girl for a week if she so much as touched the NINJA STAR!!!
One thing I learned is that ninja movies are BS, with all the effort and time needed to fabricate ONE of these, there is no way they would throw one every 10 seconds like in the movies!!!
