Zack Fair
Final Fantasy VII - Crisis Core

Cosplayer: Kata-san

Variant: SOLDIER 1st class uniform

Status: Complete

Condition: Not Set

Ayacon 2011

3rd July 2011: Wigs arrived My wig finally arrived, I had to go with a Sasuke wig as I couldn't find any suitable for Zack. I think it's going to be long enough (I'm hoping at least) but it's going to need a lot of styling!!! I'm panicking a bit as I've never styled a wig before, I'm mega busy with work stuff, I'm on holiday soon and Aya is looming!!!!!!!!!!!

At least I've gotten my girdle finished. All I need to do now is to style the wig, finish painting my buster sword (it's taking ages), get some scar stuff for his face, his two belts (don't ask me why he needs two belts) and a couple of zips for the boots, all in all not a ton of stuff but enough :P

1st July 2011: Mako eyes! Been along to spec savers today and got some cool contact lenses. As I need glasses/prescription lenses (-4.50 infact) I had to get some prescription coloured contacts so I ended up with Ciba Freshlook ColorBlends Colors which are made for dark eyes and I think they really work! The colour I got was Sapphire Blue.

I've completed the "girdle" using a mix of plether/PVC and craft foam. I think it's looking quite good if I do say so myself. My braces are also complete and the wig has arrived, YAY! I've never styled a wig before so this is going to be interesting...

4th June 2011: Damn impatient fingers Finally got the buster sword all base coloured after having to respray it because I picked up when it wasn't 100% dry and left a nice greasy imprint of my hand on the blade. I must say I'm quite pleased with how it turned out. I planned to use a metallic black but it was impossible to find and now the matt black actually doesn't look that bad.

The pauldrons have just had their last gesso coat so just waiting for it to all dry then time to go mad with the sandpaper and get it nice and smooth again. Then I've got to break out spray paint and get painting again!!

28th May 2011: Stored watered down PVA isnt always good So started rePVAing my sword today and there must've been more solid PVA sitting at the bottom that had dried out as now the swords covered in lots of little lumps of PVA, which isnt good. I've taken the worst of it off but I think once its dry Ill sand down the lumpy bits and start the PVAing again.

Bought some Leatherette as well to make shoe covers but having a bit of difficulty finding a suitably sized and coloured zip for Zacks shoes.

Went over the pauldrons with gesso as well to get rid of the papermache lines as much as I can.

13th April 2011: Creating the braces I made the braces that go over my shoulders using fat belts from Ebay glued to smaller belts but once I'd glued it all I hit a problem. At the front of them the belt folds up and the back of the belts was all rough leather that looked crap. So I ended up cutting the belts and regluing them turned around near where they bend around and I'm pretty chuffed with how it turned out.

I was punching the holes manually using a hammer and the little punch tool for the poppers and I wasn't paying attention and *WHACK* smacked my thumb. After a few choice expletives I finally got it completed. I'm pretty happy with how it turned out but I accidently stuck some duct tape to my belt and managed to take off a bit of the leather pattern *d'oh* so I'll maybe get some leather polish and clean it up a bit.

I need to buy some rivets to finish off the detailing and then hopefully that's the braces pretty much complete WOO HOO!

1st April 2011: Pauldrons Created my pauldrons by paper mache'ing a balloon. The top image is said balloon. You might be wondering why it's a funny design but I found printer paper makes a great papermache paper and to make sure I covered it all with each layer I alternated between white and "patterned" paper. I managed to get both pauldrons out of the same balloon which I was pretty happy about.

I added a bit of craft foam to do the "extra" bits with some tin cans glued underneath to try and get it to keep it's shape. I was actually quite pleased with how the pauldrons have come out.

I did an extra layer of paper mache over the craftfoam after those pictures were taken with a layer of printer paper and then I did another layer of newspaper to even out the seams a bit more.

I think I'll try spray painting it and if it's not smooth enough I might put some gesso over the top to even it out.

28th March 2011: Modular buster sword It turns out I'll be flying down to Aya so I'll need to get my buster sword on a plane so I had thoughts of making a modular buster sword that separates into smaller sections so it fits into a suitcase.

So I tried and failed to make a modular one out of plastazote and cardboard but that failed miserably, it was miles heavier than the balsa one I'd already made and the sections just flopped about so I might just pay the extra baggage fee and get it put on as oversized luggage. So this is pretty much a non post, I just wanted to expel my frustrations.

24th March 2011: Creation of the Buster Sword I thought I might as well start a journal for progress. I've created my buster sword.

I wasn't able to find large pieces of balsa wood so I had to glue lots of littler bits together. Balsa cement is perfect for, as you could probably guess, gluing all the balsa together. I think I made the central holes a bit too big but I think they're not too bad.

I made a couple of mistakes drawing out the shapes but luckily I'll be painting over the pen so no big deal.

I also bought an acrylic tube to use as a handle that I hashed in place thanks to a lot of hot glue but I don't have a picture of this bit yet.

Zelda avatar

Zelda - 10th February 2011
I look forward to seeing this ^^, i hope i can grab a picture as i have crisis core tifa planned for ayacon ^^

Kata-san avatar

Kata-san - 16th February 2011
That would be great! Yeah I'd love to get a photo together. We definitely need to sort out a meet for all the FF people ^_^

cowiee avatar

cowiee - 12th June 2011
Journal is looking good, can't wait to see more progress :D

Kata-san avatar

Kata-san - 12th June 2011
Thanks very much. It's really slow going but I can see the light at the end of the tunnel ;)

Sketch McDraw avatar

Sketch McDraw - 28th June 2011
Here's some of the pics i used for refrence:,r:1,s:0&tx=144&ty=75,r:15,s:124&tx=33&ty=57

I mainly used these for the Bustersword as it shows the detail and shows the hight comparision so you can make it into perportion to yourself.
Hope these help :)
If you have any questions or want any tips feel free to ask.

Kata-san avatar

Kata-san - 1st July 2011
Thanks very much for the links. Funnily enough that's the reference pictures I've been using for the sword.

Numta avatar

Numta - 4th July 2011
Look forward to seeing this dude!

You'll make an epic Zack!

Unknown member avatar

Anonymous - 25th July 2011
Zack! whaaa~ <3

Kata-san avatar

Kata-san - 31st July 2011
Thanks again Numta! Hopefully now I'm back from 'olidays I'll get him finished for Aya in just over 2 weeks fuuuuuuuuu!

Sketch McDraw avatar

Sketch McDraw - 16th August 2011
I cant wait to see your Zack Costume when its done, also liking the look of your Buster Sword so far :)

Kata-san avatar

Kata-san - 16th August 2011
Thanks! I think it's maybe a bit too small (that's what she said...wait, no...) It's all done now, just in time for leaving for Aya on Thursday so hopefully get a lot of photos taken there.

Manticore Arts avatar

Manticore Arts - 24th August 2011
Saw this and went! DUDE! AWESOME! Thanks for keeping my Sephiroth company!

WarriorTeddy avatar

WarriorTeddy - 24th August 2011
nice! - wish I was there to this in-person - your buster sword looks epic!

Ino avatar

Ino - 26th August 2011
Yay Zack is awesome! I saw you guys in the Masquerade - you were both awesome! That sword of yours is fantastic too~ Great job :D

Kata-san avatar

Kata-san - 27th August 2011
Thanks everyone for the great comments!

M.Kesaiyn avatar

M.Kesaiyn - 31st August 2011
Thanks for the comment. I LOVE that Buster Sword of yours!!!

This guy is a friend of someone I used to know, and he's done "The Real Buster Sword" as he's a smith and, well...he's done two versions...

The Real Buster Sword -
The REALer Buster Sword -

Numta avatar

Numta - 1st September 2011
Saw you at Aya and you looked epic!

Kept meaning to come over and introduce myself but other stuff got in the way xD

Seriously good work fella!

birds-hate-flying avatar

birds-hate-flying - 6th September 2011 looks like you could actually kill someone with that sword. That is a very well made sword, o yes it is. Also you say that this was your first cosplay? Good grief, that's awesome.

DuskatNight avatar

DuskatNight - 27th December 2011
Great work! The Sword looks amazing!