Kit Rae Design Studio Projects Scrapbook
Below are photos of some projects we are working on or have completed at Kit Rae Design Studio.
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HIGHLANDER SAMURAI SWORDS - Duncan Macleod and Connor Macleod katanas for the Highlander Hand-Forged Series (2009) These are swords for United Cutlery's Highlander line. UC was asked to make new versions of these iconic swords in early 2008 by Peter Davis, who owns the Highlander property and the Legendary Heroes/Highlander store. KRDS was hired to do some of the design work and control drawings for United. The previous versions had been made in Spain with stainless steel blades. Being a fan of the original films, I went back and made notes of things I did not like about previous versions of these swords, and things I wanted to change. There were many details that always bugged me - the primary ones being the plastic grips with injection mold lines, the stainless steel blades, and the big manufacturer logo on the habaki. I always wanted to see a forged carbon steel Highlander sword and something that resembled real ivory for the handle material, and a scabbard that would make that Duncan sword appear out of nowhere like it did on the tv show. As is always the case, time constraints did not allow everything I wanted to accomplish but overall I am satisfied with the results based on the prototypes I have seen from United.

     

     

 

Highlander film snapshots of the Connor/Ramirez sword (©MGM)

 

Highlander - The Series snapshots with the Duncan sword (© Davis/Panzer)

The intention was to make more accurate versions than the Highlander swords previously produced. The decision was made to make basically the same Duncan sword design, but to design a new version of the Connor katana that was not an exact replica, but more combination of various versions. Over the years I had collected many photos of the props, none of these particularly great references, but that is what I used to start. None of my prop collector contacts had, or knew anyone that owned the original props, so my prop reference library and the films themselves were what I used. I did a lot of hi-res dvd screen capturing and image enhancement to clarify some details for the film 1 sword, but the decision was made to do more of a film 2 sword replica. Here is what I proposed to UC and Peter Davis for these new versions - The swords would have full tang, forged carbon steel blades, not stainless like the Spanish made versions. The hilts would be cast in hard resin so there will be no mold parting lines, and they could be finished to look almost identical to real antique ivory, with some wear to the look like they have been handled for 100 years or more.

The Spanish version of the Highlander 1 Connor/Ramirez sword (shown above). The pommel does not really resemble the film 1 sword and the collectors I know, including muself, were not happy with the sculpting. The sculpt was still better than the crappy sculpt on the original prop! UC, however, did not want another version of the H1 sword.

 

The Highlander 2 version (H2 prop shown above) is my favorite of the three versions, and the preferred look from UC's team. The new Connor/Ramirez sword will be a mix of the Highlander 1 and 2 swords, but based more on H2. Technically this this is more of a new version, not a replica.

Some of the control drawings, shown above. A few elements from film 1 are mixed in, such as the tang pin. The hilt length is from the film 2 sword and the the tsuba has been thickened to match the H1 and H2 tsuba. The nose is more bat like than the bulbous Chinese-looking dragon nose of the film handles. The antique ivory "staining" should look better than the plastic grip versions if it comes out right. The red scabbard from film 1 will be replicated for this version, with the red leather hangars like Sean Connery wore in the village scene. A different scabbard, in black, was also used in the scenes in Connor's home from film 1, but we preferred the red one.

 

For the Duncan katana, UC wanted basically a straight copy of the Spanish made sword (shown above), which is what was used in the tv show after season 1. I prefer the season 1 sword, but it was decided to continue with the more popular of the two Duncan katanas. Hopefully at some point in the future the season 1 version will be made. UC's will not have a mold line on the hilt, nor any big manufacturer logo in the habaki (blade fitting). The blade collar will be solid brass this time, not cast zinc and plated like the Spanish version, and I wanted the fuchi (metal collar at dragon's neck) made the same color as the ivory grip (more about that below). The Duncan scabbard, which was rarely seen being worn in the show, will not be a traditional wood scabbard, but a flat leather scabbard with a sort of shoulder harness rig. Imagine what you think Duncan's scabbard would have looked like under his overcoat. That is what this is. A slim leather scabbard on a tight fitting harness that could be concealed under an overcoat.

   

     

Photos (above) of the new H2 and Duncan handle carvings in progress. The sculpt, done at United's factory, went through several revisions but only got about 85% match to my control drawing design - mid 2008

   

3D Model Snapshots - Used to create electrodes for molds - 2008

     

 

       

Photos (above) of the first prototypes of each sword. Molds are very rough on these test shots, which is typical. They need a lot of revisions and corrections. The connor tsuba needs some shape revisions and the tang pin covers are too flat and machined looking. The Duncan tsuba is polished too much and the edge detail is lost. The finish and colors also need to be revised on both swords. The blades are not yet finished. Not bad for a first test though - 2008

 

   

Photos (above) of the Connor/Ramirez scabbard color tests and sword hangar prototype (color not correct) - 2008

       

Photos (above) of the second prototypes of each sword, likely the final versions UC will make - 2009. The handle grips are much cleaner, more detailed, and the color is the final antique ivory hue. The Connor tsuba and tang pin covers are corrected, but the Duncan tsuba and fuchi are too dark. Notice the fuchi (metal collar at dragon's neck) on the Duncan sword is the same color as the ivory grip. In most of the Highlander tv shows, up until season 5, it appeared this way, even though the actual Marto swords had a bronze color. We made one up this way in an attempt to be more screen accurate. It was decided to go back to the bronze look like the old Spanish made replica however, as UC's team agreed that it simply looked better. Hopefully UC's factory will make the productions swords even better looking than the final samples!

Thanks to John and Dom for prop pix and input, David Stokes for your Highlander knowledge and input, and Carl for sample critiques.