Tag Archives: featured

Doctor Who Sword Cane Handle

Last spring, I was approached by a local pastor for a project. He walked with a cane, and he had found a sword cane he liked, but the handle had broken off. He wanted to know if I could make him a new one.

He was a dedicated Doctor Who fan, and wanted a handle in the shape of a question mark. He also wanted his name inscribed in Gallifreyan on it, and painted in Midnight Metallic Blue to match his Doctor Who-themed automobile.

I put together a video highlighting my whole process from start to finish.

I made the handle out of some of the ash I had left over from my Game of Thrones chest. This handle would need to be strong and hold a lot of weight. The shape of the question mark made me concerned that parts of it would split no matter which way I positioned the grain. I decided to laminate two thinner pieces together with the grains running perpendicular to each other.

Preparing the boards
Preparing the boards

As you can see in the video, the shape was cut out with a jigsaw and cleaned up with a belt sander and oscillating spindle sander. I then ran it through the router table with a large round-over bit.

Cut and rounded
Cut and rounded

A Dremel and a file helped clean up and refine the shape. If you are wondering about that strange file in the video, it is a Japanese saw file. I had just gotten it and this was my first project to use it on. It rasps like butter and is easy to keep unclogged.

He wanted his name carved in Gallifreyan. Gallifrey is Doctor Who’s home planet, and the language uses a series of interlocking circles and lines to write words. I found an online Gallifreyan transliterator and plugged his name in. I adapted the result to fit the shape of the handle, and mirrored it so it was the same on both sides.

Primed
Primed

It took a few coats of filler primer and a lot of sanding to get it smooth and shiny. The last pass was a wet sanding with 600 grit sandpaper. Then I sprayed a few light coats of the Midnight Metallic Blue paint which I had ordered from an automotive paint supplier. The paint also came with its own urethane clear coat, which I applied when everything was dry.

Doctor Who Sword Cane Handle
Doctor Who Sword Cane Handle

I threaded the end onto the sword part of the cane and glued it together with epoxy. He loved the final piece. So the next time you see a preacher in the woods fighting off snakes with his Doctor Who sword cane, you know where he got it from.

Farm Table for Abundance

Last spring, Triad Stage did a production of Abundance, one of the lesser-performed plays by Beth Henley. It was directed by Preston Lane, with scenic design by Robin Vest. One of the main furniture pieces was a giant farmhouse table. I decided to build it because finding a farmhouse table this size would blow the budget, and they are usually pretty hefty.

It needed to be super sturdy but fairly lightweight, because they jumped up and down off of it, flipped it onto its side, and dragged it around on stage. To cut down on the weight, only the boards around the perimeter of the top were the full thickness; the ones on the inside were thinner, with a bit of hidden framing to sturdy them up.

Underside of the table
Underside of the table

The breadboard ends allowed me to hide the different thicknesses of wood used for the top. I positioned the legs so they would straddle the joint where the breadboard was attached so it would not snap off if the actors ever stepped on the very edge.

I also made the legs hollow. They were made from four pieces of wood with mitered edges glued together. To save time, I glued up four long pieces of wood, and when dry, cut it into the four legs.

Joinery
Joinery

The research images for the table led me to a website called “Ana White”, which also had plans for the table the designer liked. I’ve since come across several woodworking forums which resent White’s style of furniture, since it seems to be flooding the market with this kind of shabby chic table that won’t hold up to seasonal changes. Ah well, the look was right, and it was easy to slap together.

Clamp it up
Clamp it up

I experimented with some new (for me) finishing techniques to get a really aged, rustic appearance. The first step was scorching the entire surface with a propane torch and rubbing the charred wood away with steel wool. It took forever; I wonder if an oxy-acetylene torch would have been faster, or if it would have just started an unstoppable fire.

Burning the wood
Burning the wood

After that, I rubbed an oxidizing solution over the whole thing. You can find instructions on various websites; basically, you let a piece of steel wool dissolve in vinegar for a few days. Apply it to the wood with a paintbrush and it starts to darken and grey the wood over the next few hours. Once it was all done, I rubbed a coat of paste finishing wax onto the whole thing.

Final table
Final table

It ended up being a great table for the show. I could actually carry it around myself, though for the show, it was always two actors moving it. It only started loosening up during the last show, after weeks of being tossed up on its side, which placed a lot of stress on its legs.

Abundance
Abundance

 

Assassin’s Creed Tomahawk

I recently finished up a little personal project that I’ve been chipping away at since February in my vast spare time. It’s a replica of the tomahawk from the video game Assassin’s Creed. I filmed myself building it along the way, and shoved it all into a single five-minute video.

While you can find tons of images of the tomahawk online, a lot of credit goes to MoonLit Props who developed a full-scale pattern. You can see me using it in the video to trace out the pieces.

The blade is made out of MDF and gets its unique shape from the symbol in the game. It took a lot of rasping, filing and sanding to get the bevels right, followed by endless priming and sanding to make it smooth. I finished it off with some Krylon Stainless Steel spray paint, which has a fantastic faux steel look once you rub it down with some steel wool. It also has a wash of black acrylic for shading and some silver Rub’n Buff for highlights.

The handle is simply a piece of poplar cut and routed to shape. The thin strips of wrapping are actual leather, but the handle itself is suede, since I was sticking with materials I already had laying around the shop.

For the emblem carved in the side, I wanted to try out a technique that’s been rattling around in my head; mixing metallic powders with epoxy resin to mimic metal. It did not work at all as I had hoped. I’m glad I learned that on a small part of a personal project rather than relying on it for a show.

Assassin's Creed Tomahawk
Assassin’s Creed Tomahawk

All in all, I am happy with how it turned out, and now I have another fun prop to trot out at Maker Faires.

Wooden Ratchet Noisemaker: Video

Back in 2009, I made a wooden ratchet noisemaker for a show. The prop was cut. Then they wanted one for a show the next year, so I gave it to them in rehearsal; it was cut again. I published a nice Instructable showing how it was made and that was that.

I recently built a whole bunch more, so this time I shot a video of the process. I redesigned them a bit; they no longer have bolts and pegs in the body, relying instead on glue to keep them together permanently.

Interview with Ross MacDonald

Ross MacDonald has built period props and vintage books for dozens of films and television shows over the years. Check out his web page for a portfolio of his work. I recently talked with him about making props and working in the industry.

Ross MacDonald. Photograph by Greg Preston
Ross MacDonald. Photograph by Greg Preston

How did you get started doing props?

Weirdly enough, I had been doing some television-related work, even back when I was starting out as an illustrator. I was doing this thing, this was up in Toronto, called the Artisan’s Schools Program. It was a grant program. It was me and a couple other guys, we would go into the schools, and we’d start off performing poetry, I would do big drawings, and the third guy, if he was there, would do music. Continue reading Interview with Ross MacDonald