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As for gluing I used hot glue on the bottom of the inside of each chunk so that it was touching only the expanding foam to keep the sword together and then used super glue around the seams to reinforce the bond and make sure that the sword wouldn't break if the expanding foam ripped. Also since I printed the tip at 0% infill and expanding foam struggled to fit inside I applied a liberal amount of superglue on the tip to prevent it from breaking. That would probably be easier to gather than building this thing. The Hollow Knight's helmet is one of the most iconic pieces of the character which is why the most effort has to go into it. So here we go... Wrap the remainder of the dowel rod (your handle, essentially) with generous amounts of duct tape to close the slit and keep everything in place. Finish up your structure by covering any loose or rough areas with duct tape. Cover your needle with 1-2 layers of Plasti-Dip, then spray with silver spray paint. Lastly, tie your white paracord through the hole of your oval piece (the “eye” of your needle) to act as your silk rope.
Finally we begin the actual prop making of the project! The Nail is the first part of the project I built and is the origin of my spiral into madness. It is the sword that the Hollow Knight uses thought the game and it progressively gets upgraded throughout. I thought this model would look really good and the realistic damage that the model has really helped the vibe of the overall costume that I had no idea I was about to make You may have realised that the print already has a texture. But if you are like me and had a bunch of print errors or have holes in your print or not all the parts line up correctly then you can add an extra layer of texture. And I recommend doing this even if your print came out flawless because of how simple it is to apply extra texture. This is the longer style with the engravings on it. It is much easier to make at the cost of being very flimsy and making it very hard to bend over. However you can get this to your exact body shape with a hair dryer which is a pretty big plus.Grey Non See-Though Fabric (This is used for the cape so get a 2m piece. I'm 6' 6" and that was enough to reach the floor for me) This belt is used to tie together all the oddities and references, and it's rather simple. I used the image of a template I found online as a guide (No there was not a printable version it is literally just the image I worked off of). Fold the bottom and inner edges of your cape inward and sew them down. This will keep them from fraying and give your cape a “finished” look, however, if you would like a more raw look to your cape, you can leave your edges as they are. I chose to sew down my inner edges, but since I cut a leaf-like pattern out of the bottom, I left the bottom raw.
No cost too great. No mind to think. No will to break. No voice to cry suffering. Born of God and Void. You shall seal the blinding light that plagues their dreams. You are the Vessel. You are the Hollow Knight." I will also mention in this step that you should 3D print out the stamp for the "wax seal" It's a very simple file with no supports and minimal detail needed. Make sure to delete one half then save the file as an stl. Once you have saved you can hit ctrl + z to restore the half you deleted. Then just delete the half you saved and save the other half. Assemble your 4 cardboard triangles by gluing them with hot glue along the edges. Reinforce with duct tape.
Step 5:
To make sure the nail doesn't collapse in on itself during proper use, I filled the inside with expanding foam. This kept the inside rigid and helped the gluing process afterwards. Just don't overfill the nail, expanding foam has its name for a reason. It can take over an hour for it to reach its maximum size.
Place your dowel rod into the hole and glue it in place. Wrap your dowel rod with duct tape and spray your finished structure with Plasti-Dip. For the stamp I just went with a basic coat of purple paint and a white drybrush to show off some of the details. A wash is very optional but do it if you want! This armor piece gets it's own step because it one of the last pieces I made so it has some variation in methods as I wanted to test something new.Printing isn't overly difficult once you have the whole digital aspect of the print finished. I had my nail printed into 5 smaller pieces that printed over the course of a week. Just make sure to monitor the prints and keep a steady flow of filament in the printers to make sure you don't need to restart a print. When I printed the nail I used 0% infill which saved on filament costs but caused more print errors so be careful!
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