I developed a few different models, and settled on the Skyward Sword. Modeled it in SolidWorks.
I traded some CAD work to a guy with a CNC wood mill to mill out some molds for the hilt.
I cast the hilt halves with dyed two-part plastic.
Here are the halves.
I milled out the back with a Dremmel.
Then I glued the halves together in this freaky looking setup. I count seven clamps.
Two halves, now sanded. Not shown: about 20 hours of white putty and more sanding.
Primer! On a Stick!
Blue! On a Stick! This photo show its color accurately.
Gold Leaf! This part I need more practice with. It sometimes looks messy, but I know the end result looks better than any paint I can find.
I cut out this blade at work on our plasma table. 5/16″ Carbon Steel. I had it Blanchard ground and then engraved it, then clear coated it. My brother shaped the edges with a hand grinder. It got banged up when I ground down the rounded parts of the tang, so the hilt could slide on.
I sanded it for real this time, removing the clear coat. This is before and after a good wet sanding.
I slid the hilt onto the blade. Here is a close-up on the engraving.
For the handle I did a 12-strand round plait, with a 4-2 under pattern. I think it looks pretty sharp. I cut the strands 3/8″ thick from some scrap. If I had cut the strands straighter than they are, the braid could be tighter in spots. I used a steel pipe as the solid handle, and wrapped leather with epoxy around the full tang for a solid friction fit.
Time for some manly stitching! I added two small bands to the leather handle to hide the seams. Die Hard is such a great movie.
From the other side. I’m really happy with how this looks.
It’s dangerous go alone…
You can see the rest of the Forest Gallery here: Link
Read on about my Pedestal of Time here: Link
Let me know what you think!