Sigurd's sword - progress stages and final result. My hubby said that we could cast it in lead/tin alloy, so I started to prepare the prototype mold out of Castilene. I sculpted the dragon head and used the jack-plane to even out the surface))) So, after my prototype sword was ready, I made a plaster mold. It had to be covered with graphite powder from inside, heated and so on before casting. We tied the halves together with stripes of cotton fabric, because any synthetic fibers could melt due to the heat. My hubby melted the alloy and poured it inside the mold... Luckily, nobody stood there when a hot alloy leaked outside the mold from the side! Never try to repeat that at home if you aren't experienced enough!!! No more home metal casting, I swear. More, the alloy appeared to be too soft, so I could easily bend it with my hands. And, of course, it was very heavy. You can see the messy casting outcome here. So I decided to learn cosplayer's techniques instead: they're MUCH safer. For all those who are curious, I used this tutorial: https://blog.adafruit.com/2014/09/18/make-and-paint-a-cosplay-sword-for-fifty-dollars/ I drew a digital pattern and ordered a laser cutting of MDF piece. I sculpted the dragon head out of Mungyo Sculpt Dry, sanded both sides of the sword, sharpened the edge, added some slashes, scratches and dents... Then I painted the sword with a silver spray paint. I made a copper elements out of a sheet of copper and out of wire, hammered them and glued onto the sword. Then I weathered the whole piece with 2 brown colors: a greenish shade and a reddish one. I used a thinned paints and a sponge to apply them. I wrapped a piece of leather around the grip, and that was all. I'm really pleased with the outcome! Cosplay technologies rock not only for people but for dolls too!
