Start by stenciling the basic shape of the Monado onto construction paper.
Cut out the stencil.
Cut out the gaps that exist in the monado. One at the bottom of the handle, a big circle above the handle, and two openings in the blade portion.
The Monado is built in layers. First, cut out two pieces (of 1/8″ PVC sheet) of the stencil to serve as the inner most layers. DO NOT GLUE ANYTHING YET. If the sword is fully constructed and glued now, then it will be very difficult to route the lighting.
Next, Cut out two pieces of the next layer, which will add the depth (see above picture).
Cut the stencil into the above separate pieces, and transcribe them onto the PVC sheet, twice (for both sides of the Monado).
This pieces will be added as shown above, leaving roughly a 1/8″ gap for the EL wire.
The picture above shows all the PVC sheets lined up.
Next, drill holes in the following areas of of the Monado, This will serve to route the EL wiring.
Cut out the gap for the battery pack on the inner layers.
Cut only enough so the battery pack is flush.
Route the EL wire as shown above. This is step where gluing should occur. (I used 24′ EL wire and it was roughly enough to cover the whole route)
Using tape, cover the EL wire. This is to prep it for painting.
Remove the tape to reveal lighting.
FULL BUILD LOG PDF AVAILABLE HERE: Monado_Build_Tutorial.pdf