Every Halloween we make our costumes. This year my son (6) chose Link and my daughter (8) chose Fi, the spirit of the Master Sword. We wanted to make the shield and sword sturdy enough, but not out of a mold and plastic. So we went with mostly wood with some Sculpey accents. We also wanted the kids to be able to do a lot of the work.
First I wanted the shield to be a bit curved. There are many complicated tutorials on how to bend wood online, but I thought I could bend some plywood if I got it wet, bent it, and let it dry. So we did. This was a lot of fun for my boy, and Peter for that matter. This technique worked a bit too well, so we had to flip it over a few days later and weigh it down in the opposite direction.
Then I made some templates from a photo in my sons Zelda book. I printed them out and my son helped trace it onto the wood. I scaled it down for a 6 year old.
Since we don’t have a proper wood shop, we just jigsawed the shield out.
Lots of drilling and jigsawing. Hopefully you have better suited tools.
We sanded the inside part with little files.
Then we glued the main parts together…
Cut out the triforce and sanded the edges with the neighbors belt sander…
And on to the sculpey details. I used my favorite ceramic tools and some old tricks I learned at the Neverhood (using rubbing alcohol to smooth, be sure to use outside, with a breeze.)
I worked on the template with a cutting board underneath.
Then I printed the bird on some thick card stock and made a template which I used to paint the bird on the shield.
As for the sword we used the neighbors belt sander again, upside down, as shown in this great video.
Then my son manually sanded it more.
Then I put sculpey on it and made some simple impressions with a wood block. If I did this again, I would make this part much thinner.
Then my son and I painted it. Took a few coats, but painting is fun for 6 year olds.
My amazing mother in law knitted the chain link (it’s peeking out of the tunic in various places).
I sewed the tunic and hat on the Featherweight she gave me (she has 4 of them but I got the prettiest one.)
Here is the shield template if you decide to make one, scale it up for a bigger shield.
Fi’s costume doesn’t need much of a tutorial. It’s mostly a bunch of sewing trial and error (many!) We found some great face paint online and a massive gem which we set into a sculpey triangle. We chose to do a wig instead of plastic looking hair because it looked better and was easier by far. We also gave up on the grass ribbon which kept falling down. I probably should have found some way to sew it onto the leggings…
Also, an 8 year old can help sew a lot more than a 6 year old.
Good luck if you are making either of these!