The Stone Smasher: A Goron Masterpiece#
In The Legend of Zelda: Breath of the Wild, the Stone Smasher is a massive weapon favoured by the Goron race. Unlike the elegant Royal Claymore or the magical elemental blades, the Stone Smasher has a rugged, industrial aesthetic that suggests it might be just as at home on a construction site as a battlefield.
The in-game description reads: "A Goron-made two-handed weapon designed to resemble a hammer. The sheer weight of this weapon makes it slow to wield but devastating to objects and opponents alike." With its distinctive look and and weathered appearance, this weapon presented some unique challenges in paint and realism that was a real learning experience.
thanks to my little guy for grabbing these in game screens outside Hyrule Castle - where a Stone Smasher can be found in a secret room. Google it.
At just over 1.5 metres in length and a significant bulk, I really wanted to create a significant prop. This is my most ambitious prop creation to date, combining laser-cut cardboard with extensive 3D printing to create a prop that looks like it could actually smash some stone!
Planning and Design Approach#
Unlike previous projects where I started with 2D templates in Illustrator, the Stone Smasher was designed entirely in 3D from the outset. Using Fusion 360, I created a complete model of the weapon, accounting for how different components would fit together and how the finished prop would be assembled. This model by Krulknul was a useful reference (and is very nicely done) and helped with some of the detail in my Fusion 360 model.
This 3D-first approach allowed me to plan the integration between the laser-cut cardboard blade section and the 3D printed components with much greater precision than my previous builds. This build pushed the limits of my Prusa Mini's build volume so I carefully designing components that would fit while minimising the number of components and still staying true to the reference material.
Building the Blade#
Learning from my mistake with the Great Thunderblade (where I used dense board that made the finished prop too heavy), I returned to corrugated cardboard for this build, but with a twist - using laser cutting for precision, I hollowed out the blade, to save on cardboard and keeping the weight (and laser cutting cost) manageable.
From 3D Model to Laser Cut Layers#
Having created the complete model in Fusion 360, I used a tool called "Slicer for Fusion 360" (which unfortunately is no longer supported) to slice the blade portion of the model into layers. This generated EPS files that I could then bring into Illustrator for preparation for laser cutting.
This technique allowed me to hollow out the center of the blade, saving both weight and material costs while maintaining structural integrity. The precision of the laser cutter meant that all the geometric patterns and cutouts were perfectly executed - something that would have been incredibly difficult and time-consuming to achieve by hand.
Connecting to 3D Printed Components#
One of the most challenging aspects was designing how the laser-cut cardboard sections would connect to the 3D printed components at both the top (hammer head) and bottom (handle connection).
I designed specialized 3D printed "caddies" that the cardboard layers could slot into, creating a secure connection between the different materials. This hybrid approach allowed me to use the most appropriate material for each section of the build.
For structural stability, an aluminum pole runs through the center of the blade and down into the handle, providing the strength needed for such a large prop while keeping the weight reasonable.
Building the Handle and Hammer Head#
The handle and hammer head components were where the 3D printing really shone in this build. The final model got sliced or seperarated into a total of 31 separate pieces.
Massive 3D Printing Undertaking#
The hammer head alone consisted of four separate pieces that maxed out my printer's build volume. In total, the 3D printing for this project took almost two full weeks to complete - by far the most extensive printing I've done for a single prop.
Many of the handle components were designed to interlock, creating a segmented look that matches the industrial aesthetic of the in-game weapon. Each segment was printed separately and could be painted individually before final assembly, allowing for much more detailed finishing work.
Industrial Aesthetic Through Paint Techniques#
For this build, I wanted to capture the worn, industrial look of the Stone Smasher as it appears in the game. This led me to research and experiment with various weathering and aging techniques.
I used a multi-layered painting approach where each 3D printed component received:
- A base coat of chrome/metallic paint
- The main color layer(s)
- Weathering effects to show wear and tear
One innovative technique I discovered was using toothpaste as a masking agent! Before applying the final color coat, I dabbed toothpaste in areas where I wanted the "paint" to appear worn away. After painting, I simply washed off the toothpaste, revealing the metallic layer underneath and creating a realistic chipped paint effect.
Additionally, I used rough sandpaper to create scratches and wear marks on edges and corners, further enhancing the used, battle-worn appearance of the weapon.
Bringing It All Together#
With all components printed, painted, and prepared, the final assembly brought everything together into the finished prop.
Assembly Process#
The build came together in two main sections:
- The blade and hammer head section, with the laser-cut cardboard layers slotting into the 3D printed caddies
- The handle section, with its many individual 3D printed components assembled around the central aluminum pole
These two major sections were then joined, creating the complete Stone Smasher. Despite its size, the careful material choices and hollow design keep it manageable, if not exactly lightweight!
Final Detailing#
Once assembled, final weathering and touch-ups were applied to ensure a consistent look across the entire prop. The distinctive orange and blue geometric patterns on the blade were carefully painted to match the game reference, with subtle weathering to maintain the aged appearance.
The Finished Stone Smasher#
The completed Stone Smasher stands just over 1.5 metres tall, a massive prop that truly captures the imposing nature of its in-game counterpart. The combination of precise laser-cut patterns and detailed 3D printed components creates a prop that looks incredibly accurate to the game.
I'm particularly proud of the weathered, industrial aesthetic achieved through the multi-layered painting and aging techniques. These details really sell the idea that this is a functional tool used by the Goron for both construction and combat.
Award-Winning Recognition#
I was thrilled to enter this prop in the competition at the 2024 OzComicCon, where it won the Wildcard section! This recognition validated the months of work and experimentation that went into creating what is undoubtedly my most ambitious prop project to date.
Downloads#
For those interested in creating their own Stone Smasher, I'm sharing all the design files:
Final Thoughts#
The Stone Smasher was an epic project! Combining digital design, 3D printing, laser cutting, and advanced finishing techniques, I was able to create a prop that exceeds what would be possible with any single technique alone.
Working in 3D from the outset helped immensley, especially when integrating different materials and fabrication methods. It also reinforced that sometimes the most effective techniques (like the toothpaste masking trick) can be surprisingly simple.
For those following my Legend of Zelda weapon recreations, this project brings together everything I've learned from previous builds while adding new techniques that I'll undoubtedly continue to refine in future projects.
Explore my other Legend of Zelda weapon recreations in the Swords-n-Stuff collection below.