Longsword Prop Scaling Calculator
Scale Average adult's Longsword to your exact height. Canonical overall length is 110 cm (3'7"). Enter your height below to get every dimension proportionally adjusted for your build.
Longsword reference dimensions by height
Pre-calculated Longsword proportions for common cosplayer heights. All measurements are scaled from Average adult's canonical height of 178 cm (5'10").
| Dimension | Canon (178 cm) | 155 cm (5'1") | 165 cm (5'5") | 175 cm (5'9") | 185 cm (6'1") |
|---|---|---|---|---|---|
| Overall length | 110 cm (3'7") | 96 cm (3'2") | 102 cm (3'4") | 108 cm (3'7") | 114 cm (3'9") |
| Blade length | 85 cm (2'9") | 74 cm (2'5") | 79 cm (2'7") | 84 cm (2'9") | 88 cm (2'11") |
| Handle length | 25 cm (9.8 in) | 22 cm (8.7 in) | 23 cm (9.1 in) | 25 cm (9.8 in) | 26 cm (10.2 in) |
| Guard width | 20 cm (7.9 in) | 17 cm (6.7 in) | 19 cm (7.5 in) | 20 cm (7.9 in) | 21 cm (8.3 in) |
How to build a Longsword cosplay prop
Build notes for a sword-class prop at 110 cm (3'7") canonical scale. Adjust proportions to your height using the calculator above. At this size, weight management and transport are your biggest challenges.
Materials
You'll want 10mm EVA foam for the blade core and 6mm for beveled edges and crossguard details. Grab a wooden dowel or 1/2-inch PVC pipe for the structural spine (it runs through the handle into the blade). Bond everything with Barge contact cement, not hot glue. Hot glue melts at outdoor cons, and you'll learn that the hard way if you skip the Barge. For a harder surface finish, layer Worbla thermoplastic over the foam.
Construction
Start by tracing your scaled dimensions onto a full-size paper template. Cut two blade halves from 10mm foam, channel out the center for your dowel core, and cement them together. Once dry, bevel the blade edge with a Dremel or belt sander (40-grit, then 120-grit). Build the crossguard and pommel as separate pieces so you can paint them independently. Test-fit everything before gluing.
Finishing
Seal the foam with 2 to 3 coats of Flexbond from Rosco, sanding lightly between coats. It gives a smoother base than Plasti Dip and stays flexible. Prime with Rust-Oleum 2X spray primer, then base coat in metallic acrylic. Dry-brush silver highlights on the edges, add a black acrylic wash for depth, and clear coat with matte polyurethane. The matte finish looks way more like real steel than gloss.
Build it right from the start
This calculator gives you the dimensions. Costumary tracks your full build: references, materials, budget, timeline, and progress, all in one workspace.
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Frequently asked questions
How big should a Longsword cosplay prop be?
The canonical Longsword overall length is 110 cm (3'7"), based on Average adult at 178 cm (5'10"). For a cosplayer who is 165 cm, proportional scaling brings the overall length to about 102 cm. Use the calculator above to get exact dimensions for your height.
What material should I use for a Longsword cosplay?
At 110 cm canonical length, the Longsword is a large prop. EVA foam is the best choice for builds this size. It keeps the weight under 2.5 kg, is convention-safe, and shapes easily with a heat gun. Use a PVC pipe or wooden dowel core for rigidity, and seal with Plasti Dip or contact cement before painting.
How long does it take to build a Longsword cosplay prop?
A full-size Longsword at 110 cm typically takes 40 to 80 hours spread over 2 to 4 weeks. Pattern drafting and templating takes the longest. Budget extra time for painting and weathering since large props need multiple coats and drying time between each.
How much does it cost to build a Longsword prop?
Expect $60 to $120 in materials for a foam-based Longsword. That covers EVA foam sheets ($20 to $40), contact cement or barge ($10 to $15), a PVC or dowel core ($5 to $10), primer and paint ($15 to $25), and finishing supplies like Plasti Dip or clear coat ($10 to $20). You can cut costs by using thinner foam for non-structural sections.